Polaris Sprotsman 700 User Manual

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WELCOME

Thank you for choosing Polaris, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles.

We believe Polaris sets the standard of excellence for all recreational vehicles manufactured in the world today. Many years of experience in engineering, design, and development have gone into making your Polaris vehicle the finest machine we’ve ever produced.

Follow the instructions and recommendations in this Owner’s Manual for safe and enjoyable operation of your vehicle. Your Owner’s Manual contains instructions for minor maintenance. Major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician.

Your Polaris dealer knows your vehicle best and is interested in your complete satisfaction. Return to your dealership for all of your service needs during, and after, the warranty period.

Polaris also takes great pride in our PAA (Parts Apparel and Accessories) which are available on our online store www.purepolaris.com. Have your accessories and clothing delivered right to your door!

Polaris and Polaris The Way Out are registered trademarks of Polaris Industries Inc.

WARNING

Failure to follow the warnings contained in this manual can result in severe injury or death.

A Polaris ATV Pro 500 is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings before operating a Polaris ATV Pro 500.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Safety Training

When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.

NOTE: Illustrations used in this manual are for general representation only. Your model may differ.

TABLE OF CONTENTS

Vehicle Identification Numbers 6. . . . . . . . . . . . . .

Vehicle Specifications 7. . . . . . . . . . . . . . . . . . . . . .

Safety 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding Warnings 9. . . . . . . . . . . . . . . . . . . . . . . . .

Key Safety Issues 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Decals and Locations 14. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Safety 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features and Controls 44. . . . . . . . . . . . . . . . . . . . .

Controls 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre Ride Inspection 62. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Break-In Period 63. . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrying Loads 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Noise Emission Control System 69. . . . . . . . . . . .

Riding 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre Ride Inspection 70. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Riding Tips 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

Maintenance and Lubrication 82. . . . . . . . . . . . . . .

Periodic Maintenance Schedule 82. . . . . . . . . . . . . . . . . .

Lubrication Recommendations 88. . . . . . . . . . . . . . . . . . .

Maintenance Record 92. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Systems 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lights 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plugs 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Immersion 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Arrestor 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PVT 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side Panel Removal 130. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 131. . . . . . . . . . . . . . . . . . . . . . . . . .

Trouble Shooting 135. . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram 140. . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBERS

The frame vehicle identification number (VIN) (1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are essential to its recovery and identification.

NOTE: Record your vehicle’s ID numbers in the spaces provided. Remove the spare key and store it in a safe place. Your key can be

duplicated only by mating a Polaris key blank with an existing key. NOTE: If both keys are lost, see your dealer for ignition switch replacement.

Vehicle Model Number:

Frame VIN:

Engine Serial Number:

Dealer Imprint:

VEHICLE SPECIFICATIONS

SPORTSMAN 700

Gross Vehicle Weight 1240 lbs. Fuel Capacity 4.75 U.S. Gallons Towing Capacity 1500 lbs Hitch Tongue Capacity 150 lbs Overall Length 85” Overall Width 46” Overall Height 47” Wheelbase 50.75 Ground Clearance 11” Dry Weight 740 lbs Minimum Turning Radius 71.5” Engine Oil Capacity 2 Quarts Coolant Capacity 3.2 Quarts Engine EH68ALOE1 Displacement 683 Bore x Stroke 80 x 68 Pilot Jet 45 Main Jet 155 Needle Jet P-6(829) Jet Needle 4HB41-4 Pilot Screw 1.5 Alternator Output 300 Watts @ 3000 rpm Compression Ratio 9.78:1 Starting System Electric Carburetor BST 34mm Ignition System CDI Ignition Timing 34 BTDC @ 3500 RPM Spark Plug / Gap RC7YC / 0.9 mm / .035 in Lubrication System Pressurized Wet Sump Driving System Type 4 Wheel Independent Shaft

VEHICLE SPECIFICATIONS

SPORTSMAN 700

Shift Type Side Lever (High, Low, Neutral, Reverse,

Park) Gear Reduction - Low 7.5/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 2.89/1 Drive Ratio - Front: 3.82/1 Drive Ratio - Final 3.10/1 Tire Size - Front 25 x 8 - 12 Tire Size - Rear 25 x 11 - 12 Front Brake Hydraulic Disc Rear Brake Hydraulic Parking Brake Hydraulic lock, all wheel Headlight (watts) 1 - Single Beam on Handlebar (50)

2 - Single Beam on Grill (27) Taillights (watts) 8.26 Brake Light (watts) 26.9 Instrument Cluster LCD

Clutching and Jetting Charts

Altitude AMBIENT

TEMPERATURE

Meters

(Feet)

Altitude Shift

Meters

(Feet)

(6000-12000)

0-1800

(0-6000)

1800-3700

(6000-12000)

0-1800

(0-6000)

1800-3700

Weight

20-56

PN 5631315

20-54

PN 5631214

EBS models require no helix / spring adjustment

Below 40° F

Below 5° C

175 162.5

150 140

Drive Clutch

Spring

Blue/Green

PN 7041157

Blue/Green

PN 7041157

Driven Clutch Spring

White/Yellow PN 7041635

+40°Fand above +5°C to & above

Helix*

EBS

PN 5132751

EBS

PN 5132751

SAFETY

Understanding Warnings

The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

SAFETY

Key Safety Issues

Protect Your Sport

Know all local, state/province riding laws; Respect your vehicle; Respect the environment; and You will gain the respect of others. We also advise you to strictly follow the recommended maintenance

program as outlined. This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals.

All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

Illustrations included in this manual are general representations of parts having a similar function. Your model may differ.

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles

including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.

SAFETY

Key Safety Issues

SERIOUS INJURY OR DEATH can result if you do not follow these instructions:

 Read this manual and all labels carefully and follow the operating

procedures described.

 Never operate an ATV without proper instruction. Take a training

course. Beginners should receive training from a certified instruc-

tor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

 Never allow anyone under 16 years of age to operate this ATV.  Never permit a guest to operate this ATV unless the guest has read

this manual and all product labels, and has completed a certified training course.

 Always avoid operating an ATV on any paved surfaces, including

sidewalks, driveways, parking lots and streets.

 Never operate an ATV on any public street, road or highway, even a

dirt or gravel one.

 Never operate an ATV without wearing an approved helmet that fits

properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

 Never consume alcohol or drugs before or while operating this

AT V.

 Never operate at excessive speeds. Always travel at a speed which

is proper for the terrain, visibility and operating conditions, and your experience.

 Never attempt wheelies, jumps or other stunts.  Always inspect your ATV each time you use it to make sure it is in

safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

 Always keep both hands on the handlebars and both feet on the

footrests of the ATV during operation.

 Always go slowly and be extra careful when operating on unfamil-

iar terrain. Always be alert to changing terrain conditions when operating the ATV.

 Never operate on excessively rough, slippery or loose terrain.  Always follow proper procedures for turning as described in this

manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

 Always have the ATV checked by an authorized Polaris dealer if it

has been involved in an accident.

SAFETY

Key Safety Issues

 Never operate the ATV on hills too steep for the ATV or for your

abilities. Practice on smaller hills before attempting larger hills.

 Always follow proper procedures for climbing hills as described in

this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed.

 Always follow proper procedures for going down hills and for brak-

ing on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

 Always follow proper procedures for crossing the side of a hill as

described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

 Always use proper procedures if you stall or roll backwards when

climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.

 Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

 Always be careful of skidding or sliding. On slippery surfaces,

such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

 Avoid operating the ATV through deep or fast flowing water. If

you cannot avoid water which exceeds the recommended maximum depth (pg. 78), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes.

 Wet brakes may have reduced stopping ability. Test your brakes

after leaving water. If necessary apply them lightly several times to let friction dry out the pads.

SAFETY

Key Safety Issues

 Always be sure there are no obstacles or people behind you when

you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.

 Always use the size and type tires specified in this manual. Always

maintain proper tire pressure as described in this manual.

 Never modify an ATV through improper installation or use of ac-

cessories.

 Never exceed the stated load capacity for an ATV. Cargo should be

properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.

Additional Important Information...

Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the ATV substantially increase the risk of bodily injury. Please be aware that these modifications may create a substantial safety hazard.

Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power.

We also advise you to strictly follow the recommended maintenance program outlined in this manual. This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage intervals.

NOTE:

The addition of certain accessories including (but not limited to) mowers, blades, tires, sprayers, or large racks may change the handling characteristics of the ATV.

Be certain any accessories added to this ATV have been approved by Polaris.

Familiarize yourself with their function and affect on the ATV.

SAFETY

Safety Decals and Locations

NOTE:

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.

Safety Decals and Locations

WARNING

SAFETY

IF OWNER’S MANUAL IS MISSING, CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT.

1997, 2000

7079083

SAFETY

Safety Decals and Locations

SAFETY

WARNING

UNDER

Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.

NEVER operate this ATV if you are under age 16.

7078253

WARNING

 Never operate this ATV on HILLS steeper than 25 degrees

To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually.

 REVERSE operation can be dangerous even at low speeds.

Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

 Use OVERRIDE for reverse speed limiter with caution. To prevent

loss of control, never activate override button with open throttle.

 PARKING BRAKE may relax when used for more than 5 minutes.

When parking on grades, leave shift in forward.

25°

7079085

SAFETY

Safety Decals and Locations

(on rear of seat)

WARNING

SAFETY

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS.

Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible, and firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is best. For stability on rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack.

Read Owner’s Manual for more detailed loading information

7079084

SAFETY

Safety Decals and Locations

(Under Seat)

Operation of this vehicle

without the air filter element will severely damage the engine.

Clean pre-filter element often, more

frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter.

Operation of this vehicle without

engine breather filter(s) can cause engine damage. Consult owner’s manual or dealer for details.

Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

ATTENTION

and adjustments are required depending on temperature and altitude. See your Owner’s Manual.

40 to 80 F. at 0-3000 feet

(5 to 27 C. at 0-900 meters).

WARNING

NO STEP

Specific

carburetor jetting

Factory setting:

7079902

7078689

Safety Decals and Locations

SAFETY

WARNING

Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner’s Manual.

AWD Models

WARNING

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.

Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs

7079604

ALL WHEEL

DRIVE

SWITCH

Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner’s Manual.

7079780

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS.

MANUFACTURED BY: POLARIS IND INC.

DATE:

VIN:

PRINTED IN U.S.A.

7170021

7078472

TRAILER MAX WEIGHT: 1225 LBS. (556 KG) ON LEVEL GROUND 850 LBS. (368 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16KG)

7078261

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury.

1. Helmet

Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

Select an approved helmet which meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.1), or the Snell Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for proper eye protection. A pair of goggles or helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings z2.1 or VESC 8).

3. Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

4. Boots

The best footwear is a pair of strong over the calf type boots with heels, such as moto-cross boots.

5. Clothing

To protect your body, long sleeves and pants should always be worn. Riding pants with kneepads, a jersey and shoulder pads provide the best protection.

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator

does not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the

certified training course offered by Polaris Industries Inc. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner’s Manual.

For more information about the training course, contact an authorized ATV dealer or call Polaris at 1-800-342-3764.

SAFETY

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age

can lead to severe injury or death of the child. Even though a child may be within the age group for which some

ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident.

HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris ATV.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your

passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the

operator to shift position as needed during operation. It is not for carrying passengers.

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks,

paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces

may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.

HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever possible. If

you must ride on a paved surface, go slowly and do not make sudden turns or stops.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway,

even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets,

roads and highways.

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye

protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your

chances of a severe head injury or death in the event of an accident.

Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.

HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly. You should also wear: eye protection (goggles or face shield);

gloves; boots; long-sleeved shirt or jacket; and long pants.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this

ATV.

WARNING

POTENTIAL HAZARD Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can

result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility

and operating conditions; and your experience.

Operator Safety

SAFETY

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to

show off.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure

the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and

schedules described in the Owner’s Manual.

WARNING

POTENTIAL HAZARD Removing hands from handlebars or feet from footrests

during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to

control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.

HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet

on the footrests of your ATV during operation.

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar

terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without

enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar

terrain. Always be alert to changing terrain conditions when operating

the ATV.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra care when operating on excessively

rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could

result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose

terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.

Always be especially cautious on these kinds of terrain.

Operator Safety

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in

the Owner’s Manual. See page 72 . Practice turning at low speeds before attempting to turn at

faster speeds. Do not turn at excessive speed.

WARNING

SAFETY

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills

than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for

your abilities. Practice on smaller hills before attempting large hills. Never operate ATV on hills steeper than 25.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described

in the Owner’s Manual. See pages 74 through 77. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over

backwards. Never go over the top of any hill at high speed. An obstacle, a

sharp drop, or another vehicle or person could be on the other side of the hill.

Operator Safety

WARNING

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as

described in the Owner’s Manual. See page 76. NOTE: A special technique is required when braking as you go downhill.

Always check the terrain carefully before you start down any hill.

Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the

vehicle to lean sharply to one side. Go straight down the hill where possible.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have

mastered the turning technique as described in the Owner’s Manual on level ground. See page 77. Be very careful when turning on any hill.

Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s

Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or

improperly dismounting while climbing a hill.

WHAT CAN HAPPEN Could result in ATV

overturning. HOW TO AVOID THE

HAZARD Maintain steady speed when

climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply rear brake as well, and then lock

parking brake. Dismount on uphill side, or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure

described in the Owner’s Manual. See page 77.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV

to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as

large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures

as described in the Owner’s Manual.

WARNING

POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the

ATV to overturn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very

cautious in order to reduce the chance of skidding or sliding out of control.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control,

which could lead to an accident. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water. If

you cannot avoid water which exceeds the recommended maximum depth (pg 78), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes.

Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in

severe injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no

obstacles or people behind you. When it is safe to proceed, go slowly.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or

uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV

with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident.

HOW TO AVOID THE HAZARD Always use the correct size, type, and pressure as specified

on page19.

WARNING

POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this

vehicle may cause changes in handling which in some situations could lead to an accident.

HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of

accessories. All parts and accessories added to this vehicle should be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an

accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow

greater distance for braking. Always follow the instructions in the Owner’s Manual for carrying

cargo or pulling a trailer. See pages 66 through 68.

WARNING

POTENTIAL HAZARD Riding on frozen lakes and rivers. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator

break through the ice. HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water before you are

sure the ice is thick enough and sound enough to support the machine and its operator, as well as the force that is created by a moving vehicle.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV

to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as

large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures

as described in the Owner’s Manual.

WARNING

POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the

ATV to overturn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very

cautious in order to reduce the chance of skidding or sliding out of control.

SAFETY

Operator Safety

WARNING

After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage.

WARNING

Safe operation of this rider active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death.

CAUTION

Keep combustible materials away from exhaust system. Fire may result.

CONTROLS AND FEATURES

Controls

Engine Electrical Switches

WARNING

Activating the override button while throttle is open can cause loss of control resulting in severe injury or death.

1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped

OFFOFF

with a reverse speed limiter system. To obtain additional power while backing up, depress the override button. NOTE: The override switch also allows activation of AWD (All Wheel Drive) in reverse, if the AWD switch is on. When not in reverse the switch also acts as the “mode button” for the instrument cluster.

2. Main Switch - To start the engine, slide the stop switch to the center “run” position and turn the main key switch clockwise past the “on” position. Release the key when the engine starts.

3. Engine Stop Switch - The engine will not start or run when the switch is in its “off” position. Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. NOTE: Both the main switch and the emergency engine stop switch shut off all electrical power to the entire vehicle including lights. To stop the engine, slide the stop switch right or left to the “off” position.

RUN

CONTROLS AND FEATURES

Controls

Engine Throttle and Choke

WARNING

Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death.

Always contact your dealer for service repairs whenever throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident.

Always check the lever for free movement and return before starting the engine and occasionally during riding.

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is released.

This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle. In the event the throttle cable should stick in an open position, the engine will stop and power to the rear wheels will cease when the operator releases the throttle lever.

Choke

Refer to the engine starting procedure on page 64 for correct choke and throttle settings during starting.

CONTROLS AND FEATURES

Controls

Brakes

The front and rear brakes are applied by squeezing the left side brake lever toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only.

Always test brake lever travel and reservoir fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

WARNING

Never operate the ATV with a spongy feeling brake lever. Operating the ATV with a spongy brake lever can result in loss of

braking. Loss of braking could cause an accident.

CONTROLS AND FEATURES

Controls

WARNING

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

Front and Rear Brakes

The brake fluid in the master cylinder, which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (1) on the top of the master cylinder. This “eye” will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear. NOTE: When checking the fluid level, the ATV must be on level ground the the handlebars straight. If the fluid level is low add DOT 3 (PN 2870990) only.

WARNING

Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of severe injury.

CONTROLS AND FEATURES

Controls

Parking Brake

WARNING

Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the parking brake is left on while the ATV is operated.

Setting the Parking Brake

1. Put the vehicle gear selector into park.

2. Squeeze the left hand brake lever two or three times and hold it.

3. Push the park brake lock (2) into the notches on the master cylinder body. Release the brake lever.

4. To release the parking brake lock, squeeze the brake lever. It will return to its released position.

Important Safeguards

 The parking brake may relax when left on for a long period of time.

This could cause an accident.

 Do not leave the vehicle on a hill depending on the parking

brake for more than five minutes.

 Always put the gear selector in park and block the downhill side of

the wheels if leaving the ATV on a hill or park the ATV in a side hill position.

CONTROLS AND FEATURES

Controls

Foot Brake

WARNING

Use caution when applying the foot brake. Do not aggressively apply the foot brake when going forward or the rear wheels may skid and slide sideways causing loss of control.

Your Polaris ATV has a foot brake (1) provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the main brake system, especially if the main system becomes inoperative.

If the rear wheels slide, reduce brake pedal pressure to brake the rear wheels without skidding. Aggressively applying the rear brake when backing down a hill may cause rear tip over.

Brake Fluid Level

It will be necessary to check the brake fluid level for the foot brake. The reservoir is located under the RH rear cab. The fluid should be kept between the maximum and minimum marks.

CONTROLS AND FEATURES

Controls

Fuel System

The fuel tank filler cap (1) is located directly behind the handlebar. Refer to vehicle specifications on page 7 for tank capacity. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 (R+ M/2) octane.

The fuel valve is located on the left side panel and has three positions:

OFF: For vehicle storage and whenever transporting.

ON: For normal operation. RES: For reserve supply in

the event of main supply exhaustion.

NOTE: There is about a 7 to 10 mile (11.2 to 16 km) range on reserve gas. Always refill the gas tank as soon as possible after having used the reserve supply.

Always return valve to “on” position after refueling machine.

OFF

RES

Fuel Filter

The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of

operation or annually. Do not attempt to clean the fuel filter.

CONTROLS AND FEATURES

Controls

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

 Always exercise extreme caution whenever handling gasoline.  Always refuel with the engine stopped and outdoors or in a well

ventilated area.

 Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

 Do not over fill the tank. Do not fill the tank neck.  If you get gasoline on your skin or clothing, immediately wash it

off with soap and water and change clothing.

 Never start the engine or let it run in an enclosed area. Gaso-

line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

 Shut off fuel valve whenever the ATV is stored or parked.

WARNING

The engine exhaust from this product con-

tains chemicals known to cause cancer,

birth defects or other reproductive harm.

CONTROLS AND FEATURES

Controls

Automatic Transmission Gear Selector

The transmission gear selector is located on0 the right side of the vehicle directly above and forward of the engine and has five positions: high, low, neutral; reverse, and park.

To shift into “High” or “Park”, you must first depress the foot brake to activate the High/Park lock out mechanism.

When shifting out of “High” or “Park”, it is not necessary to depress the brake.

NOTE: To extend belt life, use low forward gear in heavy pulling situations and in situations where you are operating below 7 miles per hour for extended periods of time.

CAUTION

To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Depress the foot brake if shifting into high or park. Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

Always place the transmission in park with the parking brake locked whenever the vehicle is left unattended.

GENERAL RANGE OPERATION GUIDELINES:

Low Range Heavy pulling, basic operational

speeds less than 7 MPH, riding through rough terrain (swamps, mountains, etc.), low ground speeds.

High Range High ground speeds, speeds above 7

MPH.

CONTROLS AND FEATURES

Important Safeguards

 Always back slowly avoiding excessive speed and do not use the

reverse speed override switch system unless additional power is required for vehicle movement.

 Avoid turning at sharp angles in reverse.  Avoid backing on steep inclines.

Light Switches and Indicator Lights

WARNING

This ATV is not equipped with highway approved lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

Oil Pressure Switch

Some 2002 Sportsman 700 ATVs were produced without an oil pressure switch as standard equipment.

If your model has this switch, it will be located on the LH side of the engine next to the oil filler tube. It is not to be confused with the engine temperature switch that is located on the same side but higher up on the engine.

If the oil pressure switch is not installed on your engine, the oil pressure warning is not active and the diagnostic mode feature is not valid.

Engine Temperature Switch

Oil Pressure Switch

CONTROLS AND FEATURES

Features

Exclusive AWD System (All Wheel Drive)

Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) system which is activated by a switch (1) on the right handlebar. When the switch is “off” the ATV is in 2 wheel drive at all times. When the switch is “on” the ATV is in All Wheel Drive and the AWD indicator(2) will light.

When in AWD, the front wheels will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage.

NOTE: The override switch also allows activation of All Wheel Drive (AWD) in reverse, if All Wheel Drive switch is on.

There is no limit to the length of time the vehicle may remain in All Wheel Drive.

The All Wheel Drive switch may be turned on or off while the vehicle is moving. If the switch is turned off when the front hub is driving it will not release until the rear wheels regain traction. To protect the front drive system, the AWD will not engage if the engine is running higher than 3100 RPM. Once enabled, the AWD system will work at any RPM.

CAUTION

Do not switch on All Wheel Drive if the rear wheels are spinning. This may cause severe drive shaft and hub damage.

CONTROLS AND FEATURES

Features

Exclusive AWD System (All Wheel Drive)

Engage the All Wheel Drive switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the All Wheel Drive switch on. NOTE: If the instrument cluster is not registering a proper gear indication, AWD can still be enabled by pressing the mode/override button.

Disengaging Wheel Hubs

When backing or while in All Wheel Drive and then going forward again, the AWD hub may remain engaged. If the hub remains engaged it can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward again.

NOTE: If the hub remains engaged after following these instructions return the ATV to your dealer for service.

Switches

The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also switches the lights from Hi to Lo on models equipped with Hi-Lo beams. NOTE: The lights will not work unless the key is in the on position and shut off switch is in the “run” position.

CONTROLS AND FEATURES

Features

Instrument Cluster

Your Sportsman 700 is equipped with an instrument cluster which senses vehicle speed from the right hand front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed at approximately 7 to 9 mph. Refer to page 44 for additional information.

1 Rider Information Center 2 Speedometer needle - in addition to depicting vehicle speed, this

needle will flash indicating a fault condition.

3 Speedometer

CAUTION

Do not wash the instrument cluster with a high pressure washer. Water under high pressure may enter the instrument cluster and cause damage to the electronic components. Wash the unit by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow gasoline to remain on the instrument cluster.

CONTROLS AND FEATURES

Features

Rider Information Center

The rider information center is located in the lower portion of the instrument cluster.

1 Gear Indicator -

As the shift lever is moved, this will indicate the gear the machine is in:

H = High Range L = Low Range N = Neutral R = Reverse P = Park

E or blank = Error

- Most of the time, this error message will indicate you are inbetween gears. It can, however, also indicate the transmission

switch is broken. 2 High Engine Coolant Temperature 3 Low Oil Pressure 4 Hour Meter 5 Service Interval 6 Low Battery and over voltage NOTE: All segments of the rider information center will light up for

2.5 seconds at start-up.

CONTROLS AND FEATURES

Features

Rider Information Center

The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button which is found on the LH handlebar is also

the “mode button”. NOTE: If using the mode button to program the rider information center, or to toggle through the options, the machine cannot be in reverse.

Mode 1 - Odometer

This will record the amount of miles the ATV travels.

Mode 2 -Trip Meter

To reset the trip meter, select the tripmeter mode. Press and hold the mode button (override button) until the total changes to “0” . NOTE: In the Rider Information Center, the trip meter is displayed with a decimal point, the odometer is displayed without a decimal point.

Mode 3 - Hour Meter

This mode logs the total hours the engine has been in operation.

CONTROLS AND FEATURES

Features

Rider Information Center

Mode 4 - Programmable Service Interval

The purpose of the programmable service interval is to provide the consumer and their dealer with a convenient way to schedule routine maintenance. When your vehicle leaves the factory, this feature is turned “OFF”. You must enable this feature if you intend to use it to track maintenance requirements.

The service interval mode operates by service hours. To set the hours, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. At this point, each time the button is pressed, the setting will increase by one hour. Pressing and holding the button will allow the numbers to escalate much faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to “0”. At this point you can re-attempt to set the number.

Once the service interval mode is set, it will count down to “0” according to the hours your engine is running. When the counter times out at “0”, the wrench icon will flash quickly for 5 seconds every time the vehicle is started as a reminder that the next periodic maintenance is due.

If the service interval is enabled on your ATV and you wish to turn it off, toggle to the service interval mode. Press and hold the mode button for approximately 7 seconds until the word “OFF” appears in the Rider Information Center.

CONTROLS AND FEATURES

Features

Rider Information Center

Diagnostic Mode

CAUTION

The diagnostic mode is for informational purposes only. Your dealer is fully equipped with the knowledge and special tools required to keep your machine running. Please return your ATV to your dealer for all major repairs.

To enter the diagnostics mode:

1. Turn the key switch off and wait 20 seconds.

2. Set the park brake and shift the transmission to neutral.

3. Hold the mode/reverse override button as you turn the key switch on.

The initial screen displayed looks similar to this illustration and is referring to the software version currently installed in your machine. This information is only briefly displayed.

Use the mode/reverse override button to toggle through the diagnostic screens.

The first screen indicates battery voltage.

CONTROLS AND FEATURES

Features

Rider Information Center

The second screen provides a full diagnostic indication of the entire oil pressure electrical circuit. Along with the letters PrSSr, there will be a box on the LH side. If the box is high, the pressure is normal. If the box is low, the pressure is low.

Screen three is the tachometer for setting idle speed. If this needs adjustment, please contact your dealer.

As long as you are in the diagnostic mode, the wrench icon will remain lit.

To leave the diagnostic mode, either shift the machine out of neutral or turn the keyswitch off and on. NOTE: Any movement of the tires will also take the machine out of the diagnostic mode.

Auxiliary Power Outlet

Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights and is located on the front headlight pod.

Accessory outlets are available for all models. Contact your Polaris dealer for more information.

OPERATION

Pre Ride Inspection

WARNING

You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.

Use the following checklist to verify your machine is in proper working order each time you ride.

Item/Inspection Procedure

1. Tires - check condition and pressures

2. Fuel and oil tanks - fill both tanks to their proper levels

3. All brakes - check operation, adjustment and fluid level (includes foot brake)

4. Throttle - check for free operation and closing

5. Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

6. Engine stop switch - check for proper function

7. Wheels - check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins

8. Air cleaner element - check for dirt; clean or replace

9. Steering - check for free operation noting any unusual looseness in any area

10. Loose parts - visually inspect vehicle for any damaged components or loose nuts/bolts or fasteners

11. Operators helmet, goggles and clothing

12. Engine coolant - check for proper level at the recovery bottle

OPERATION

Break-In Period

The break in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

CAUTION

Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts.

1. Fill fuel tank with either unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2.

2. Check oil reservoir level indicated on dipstick. Add oil if necessary.

3. Drive slowly at first. Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle or sustained high speed.

5. Perform regular checks on fluid levels, controls and all important areas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found on page 62.

6. Pull only light loads.

7. Break in oil and filter. Change at 20 hours or 200 miles.

SAFE

ADD 8 OZ

OPERATION

Starting the Engine

Procedure for Starting a Cold Engine

WARNING

Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors.

CAUTION

You must allow your vehicle adequate warm up time before operating or engine damage could result.

1. Place the transmission in neutral or park and reset the parking brake.

2. Turn the fuel tank valve to ON.

3. Sit on the vehicle.

4. Pull the choke out all the way.

5. Turn the engine stop switch to RUN.

6. Turn the ignition key past the “ON” position to engage the starter.

NOTE: the choke is on “FULL” when the knob is pulled out all the way. The choke is “OFF” when the knob is pushed in. This is a variable choke and can be adjusted gradually, depending on how much choke is needed for starting.

7. Do not press the throttle while starting the engine.

8. Activate the starter for a maximum of five seconds, releasing the key when the vehicle starts. If engine does not start, release the starter and wait five seconds; then activate the starter for another five seconds. Repeat this procedure until engine starts.

OPERATION

Starting the Engine

After the Engine Starts

1. If the engine slows or stops, use of the choke at half way in will allow proper engine warm up.

2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then push the choke all the way in.

Cold Weather Operation

Polaris offers an engine heater kit for cold operation. If you use your ATV all year round, it is important to check your oil

level frequently. A rising oil level could indicate the accumulation of water in the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained.

Water accumulation increases as outside temperature decreases. The cold weather kit not only reduces moisture accumulation, but the

heater will provide quicker warm-ups and easier starting. See your dealer for more information on cold weather operation and if

the heater kit will enhance your cold weather operation.

OPERATION

Carrying Loads

Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

Maximum trailer weight - 1500 (680 kg) on level ground only with a maximum vertical hitch weight of 150 lbs. (68.04 kg). NOTE: The rear rack capacity and tongue weight should not exceed 180 lbs.

Maximum grade while trailer towing - 15°. Do not tow any trailer on a grade steeper than 15° (850 lbs on grades up to 15° ).

Your machine is equipped with a front rack, take care when loading. Improper loading of the front rack can obstruct the headlight beam, reducing night visibility. Do not obstruct the headlight beam with cargo.

Use of low forward gear is recommended in heavy pulling situations to extend belt life.

OPERATION

Carrying Loads

WARNING

Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death.

2/3 of Load on Rear Rack

1/3 of Load on Front Rack

Important Safeguards

To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below:



REDUCE SPEED AND ALLOW GREATER DISTANCE

FOR BRAKING WHEN CARRYING CARGO.

 CARGO WEIGHT DISTRIBUTION should be 1/3 on the

front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on one rack only increases the possibility of vehicle tip over.

 HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations which may require backing downhill.

 ALL LOADS MUST BE SECURED BEFORE MOVING

VEHICLE. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

OPERATION

Carrying Loads

 LOADS MUST BE CARRIED AS LOW ON THE RACKS

AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

 OPERATE ONLY WITH STABLE AND SAFELY AR-

RANGED LOADS. When handling off-centered loads which cannot be centered, securely fasten load and operate with extra caution. Always attach the tow load to the hitch point designated for your ATV.

 EXTREME CAUTION MUST BE USED when operating

with loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.

 DO NOT BLOCK THE FRONT HEADLIGHT BEAM when

carrying loads on the front rack.

 DO NOT TRAVEL FASTER THAN THE REC-

OMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

NOISE EMISSION CONTROL

SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for

purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or

(2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING:

1. Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases.

2. Removal or alteration or the puncturing of any part of the engine air induction system.

3. Replacement of any vehicle parts with parts not in compliance with federal regulations.

4. Lack of proper maintenance.

CAUTION

Remember, exhaust system components are very hot during and after use of ATV. Serious burns can result if hot components are touched.

 Do not touch exhaust system components. Serious burns can re-

sult.

 Be especially careful when traveling through tall grass. The poten-

tial for fire exists.

USFS Approved Spark Arrestor

Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A.

RIDING

Pre Ride Inspection

WARNING

You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.

Use the following checklist to verify your machine is in proper working order each time you ride.

Item/Inspection Procedure

1. Tires - check condition and pressures

2. Fuel and oil tanks - fill both tanks to their proper levels

3. All brakes - check operation, adjustment and fluid level (includes foot brake)

4. Throttle - check for free operation and closing

5. Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

6. Engine stop switch - check for proper function

7. Wheels - check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins

8. Air cleaner element - check for dirt; clean or replace

9. Steering - check for free operation noting any unusual looseness in any area

10. Loose parts - visually inspect vehicle for any damaged components or loose nuts/bolts or fasteners

11. Operators helmet, goggles and clothing

12. Engine coolant - check for proper level at the recovery bottle

RIDING

Safe Riding Tips

Riding Position

1. Sit upright with both feet on the footrests and both hands on the handlebars.

2. After starting the engine and allowing it to warm up, shift the transmission into gear.

3. Check your surroundings and determine your path of travel.

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening.

6. Drive slowly, practice maneuvering and using the throttle and brakes on level surfaces.

RIDING

Safe Riding Tips

Making Turns

Practice making turns at slow speeds.

To turn, steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. The same leaning technique should be used for turning in reverse.

WARNING

Avoid turning at sharp angles in reverse as tipover and severe injury may result.

RIDING

Safe Riding Tips

Riding on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always:

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids.

3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

4. Driving with All Wheel Drive (All Wheel Drive) engaged can assist in controlling the vehicle in slippery areas.

5. Never apply brakes during a skid. Complete loss of ATV control can result.

6. Do not operate on excessively slippery surfaces if possible to avoid.

7. Always reduce speed and use additional caution.

CAUTION

Severe damage to drive train may occur if the Demand Drive is engaged while the wheels are spinning.

WARNING

Failure to exercise care when operating the ATV on slippery surfaces can be dangerous.

Loss of tire traction and vehicle control can result in an accident, including an overturn.

RIDING

Safe Riding Tips

Traveling Uphill

25 Maximum

WARNING

Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death.

Whenever traveling uphill always travel straight uphill and:

1. Avoid steep hills (25 maximum).

2. Keep both feet on the footrests.

3. Transfer your weight forward.

4. Proceed at a steady rate of speed and throttle opening.

5. Remain alert and be prepared to take emergency action. This may include quick dismounting of the ATV.

Safe Riding Tips

Sidehilling

RIDING

Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always:

1. Slow down.

2. Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle directions.

If vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!

WARNING

Improperly crossing hills or turning on hills can be dangerous. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death.

RIDING

Safe Riding Tips

Traveling Downhill

Whenever descending a hill, always:

1. Drive directly downhill.

2. Transfer your weight to the rear of the vehicle.

3. Slow down.

4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the foot brake and its use in the event loss of

normal service brakes occurs.

WARNING

Do not travel at excessive speeds. It is dangerous and can cause loss of vehicle control and tipping, resulting in severe injury or death.

RIDING

Safe Riding Tips

Turning Around on a Hill

8’

Uphill

If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn.

1. Stop and lock the parking brake while maintaining body weight uphill.

2. Leave transmission in forward and shut off engine.

3. Dismount on left or uphill side of ATV.

4. Staying uphill of ATV, turn handlebars full left (while facing front of ATV).

5. While holding service brake, release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward.

6. Lock the parking brake and remount ATV from the uphill side, maintaining body weight uphill.

7. Restart engine with transmission still in forward, release parking brake, and proceed slowly, controlling speed with the service brake, until ATV is on reasonably level ground.

WARNING

Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV could occur resulting in severe injury or death.

RIDING

Safe Riding Tips

Crossing Streams

Your Polaris ATV can operate through water up to maximum recommended depths reaching the footrests. Before fording streams always:

1. Determine water depths and current.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.

 Avoid operating the ATV through deep or fast flowing water. If

you cannot avoid water which exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, maintain a slow and steady forward motion. Do not make sudden turns or stops and do not make sudden throttle changes.

NOTE: After running the vehicle in water, it is critical your machine is serviced as outlined in the maintenance chart beginning on page 82. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

If your vehicle becomes immersed, and it is impossible to take it to a dealer before starting, follow the steps described on page 121. It is still important the vehicle be serviced by your dealer at the first opportunity.

RIDING

Safe Riding Tips

Trail Obstacles

Keep Alert!

Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches.

WARNING

Not all obstacles are visible. Travel with caution on trails. severe injury or death can result if your machine comes in contact with a hidden obstacle.

RIDING

Safe Riding Tips

Backing Up

1. Avoid backing up on steep inclines.

2. Always back slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

6. Never activate override button while throttle is open. Loss of control may result.

NOTE: Most Polaris ATVs are equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Only open the throttle enough to maintain a desired speed.

CAUTION

Opening the throttle more than required may cause excessive fuel to build in the exhaust, resulting in engine popping and/or engine damage.

RIDING

Safe Riding Tips

Parking on an Incline

Whenever the Vehicle is Parked

1. Turn the engine off.

2. Place the transmission in park.

3. Set the parking brake.

4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above.

5. Shut off fuel supply.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart on the following pages.

Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer.

Service and adjustments are critical. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

CAUTION

Due to the nature of the adjustments marked with a  on the

following chart, it is recommended that service be performed by an

authorized Polaris dealer.

 More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.

 Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California -only emissions warranty.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours or

Miles Brake System Pre-ride Pre-ride Pre-ride inspection item Foot Brake Pre-ride Pre-ride Pre-ride inspection item Tires Pre-ride Pre-ride Inspect daily, pre-ride in-

Wheels Pre-ride Pre-ride Pre-ride inspection item Frame nuts, bolts,

fasteners

Air Filter - Pre-Clean-erPre-ride Pre-ride Inspect-Clean

Coolant/Level Inspection

Fuel and oil tanks Pre-ride Pre-ride Fill to proper levels Throttle Pre-ride Pre-ride Check operation Lights Pre-ride Pre-ride Check operation Engine Stop Switch Pre-ride Pre-ride Check operation Steering Pre-ride Pre-ride Check for free operation

 Air Box Sediment

Tube Headlamp Inspection Pre-ride Pre-ride Check operation daily; ap-

Tail lamp inspection Pre-ride Pre-ride Check operation daily; ap-

Air Filter - Main Ele-

ment

Pre-ride Pre-ride Pre-ride inspection item

Pre-ride Pre-ride Replace engine coolant

Pre-ride Pre-ride Drain deposits whenever

Weekly Weekly Inspect-Replace if neces-

When Remarks

spection item

every two years

visible

ply Polaris dielectric grease to connector when replaced

ply Polaris dielectric grease to socket when replaced

sary

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

CAUTION

Due to the nature of the adjustments marked with a  on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

 More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.

 Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California -only emissions warranty.

Item Hours or

Miles

 Transmission Oil

Level Battery 20 hrs Monthly Check Terminals/clean/

Engine breather filter

(4-cycle)

 Brake pad wear 20 hrs Monthly Inspect periodically  Front and Rear Gear-

case Oil (shaft drive)

 General Lubrication 50 hrs 3

Engine Oil - Level/

Change (4-Cycle)

20 hrs Monthly Inspect monthly; change

20 hrs Monthly Inspect-replace annually

100 hrs Monthly Check monthly and

100 hrs / 1000 miles

When Remarks

annually

check fluid level

and as needed

change annually Lubricate all fittings, pivots,

months 6

months

cables, etc. Check Level Daily; Break

in Service at 1 month. Change oil more often in cold weather use.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours or

Miles

Oil Filter(4-Cycle) 100 hrs /

1000

miles

 Engine breather

hose (4-cycle)

Carburetor Float Bowl

 Throttle Cable/ETC

Switch

 Choke (Enricher)

Cable Coolant strength/

pressure test system

 Drive belt 50 hrs 6

 Steering 50 hrs 6

 Front Suspension 50 hrs 6

 Rear Suspension 50 hrs 6

 Spark Plug 100 hrs 12

 Rear Axle 50 hrs 6

100 hrs 6

50 hrs 6

100 hrs 6

When Remarks

6 months

months

Replace with oil change

Inspect

Drain bowl periodically and prior to storage

Inspect-adjust, lubricate, replace if necessary; preride inspection item

Inspect, lubricate, replace if necessary

Inspect strength seasonally; pressure test system annually

Inspect, replace if necessary

Inspect daily, lubricate

Inspect-lubricate, tighten fasteners

Inspect, tighten fasteners

Inspect-replace if necessary

Inspect bearings, Lube

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

CAUTION

Due to the nature of the adjustments marked with a  on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

 More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.

 Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California -only emissions warranty.

Item Hours or

Miles

Ignition Timing 100 hrs 12

Fuel System 100

hours

 Fuel Filter 100 hrs 12

Radiator 100 hrs 12

Cooling System hoses

Spark arrestor 100 hrs 12

 Clutches (drive and

driven)

100 hrs 12

When Remarks

months 12

months

Inspect and adjust as needed

Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years.

Replace annually

Inspect/clean external surface

Inspect

Clean out

Inspect, clean

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours or

Miles Engine Mounts 100 hrs 12

Valve Clearance 100 hrs 12

 Brake fluid 200 hrs 24

 Front wheel bearings 300 hrs 36

 Idle Speed As Re-

quired

 Toe adjustment As re-

quired Headlight Aim As re-

quired

When Remarks

months

months As Re-

quired As re-

quired

Inspect

Inspect/Adjust

Change every two years

Inspect, replace if necessary

Adjust

Periodic inspection, adjust when parts are replaced

Adjust if necessary

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Item Lube Rec Method Frequency*

(1)Engine Oil Polaris

Premium 4 Synthetic 0W40

(2) Brake Fluid

(3) Transmission Oil

(4) Front Gearcase Oil

(5) Rear Gearcase Oil

(6) Front Prop Shaft U-joints

(7) Front Propshaft Yoke

DOT 3 Only

Polaris Premium Synthetic gear case lube

Premium Hub Lube

GL5 80-90 Weight Gear Lube

Grease+ Locate Fittings and

Grease+ Locate fittings and grease

Add to proper level on dipstick. See page 96.

Maintain level between fill lines. See page 47.

See Page 98 Change

See Page 99 Change

Grease

- 3 pumps maximum

Check level daily.

As required; change every two years or 200 hours

annually or at 100 hours

Change Annually or at 100 hours

Every 3 months or 50 hours

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(4) Front Gear Case

Fill plug

(5) Rear Gear Case

(6) Front Prop Shaft (U-Joints)

(3) Transmission (plug)

Fill plug

(7) Propshaft Yoke

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(8) Front Drive Axle (U Joint) (AWD Models)

(9) Ball Joint 

(10) Front A Arm Pivot Shaft

(11) Upper steering Post Bushing

(12) Upper Control ArmsGrease

(13) Lower Control ArmsGrease

(14) Rear Wheel Hub Bearing Carrier

(15) Rear Anti-Roll BarGrease

 More often under severe use, such as wet or dusty conditions.

**Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special.

+ Grease every 500 miles, or before long periods of storage or after pressure washing, or after submerging in water. Always use Polaris Premium U-Joint Lube for maximum service of these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.).

∆ When suspension action becomes stiff or after washing. NOTE: Hours are based on 10 mph average.

Grease+ Locate grease fitting and

grease with grease gun.

Locate fitting on back side of Grease **



Grease **∆



Grease **

**∆



Grease **∆

struts and grease with grease

gun.

Locate fitting on pivot shaft

and grease with grease gun.

Locate fitting on steering post

and grease with grease gun.

Locate fittings and grease Semi-

Locate fitting and grease Semi-

Every 3 months or 50 hours

annually

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(11) Steering Post Bushing

(10) Front A Arm

Pivot Shaft

Upper

(13) Lower Control Arm

(8) Axle Cardan Front Drive

(13) Lower Control Arm

(15) Rear AntiRoll Bar

(12) Upper Control Arm

(14) Rear Wheel Hub Bearing Carrier

MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance work:

Maintenance

Interval

Performed

First 5 Hrs.

25 Hrs. 50 Hrs. 75 Hrs.

100 Hrs.

Servicing

Date

Servicing

Dealer

or Person

Remarks

MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle(1), located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle.

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

To access the recovery bottle it is necessary to remove the left side panel as described on page 130.

MAINTENANCE AND LUBRICATION

Engine Cooling System

WARNING

Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.

Radiator Coolant Level Inspection

NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.

To access the radiator pressure cap:

Using the tool provided, remove the four screws securing front rack (1). Remove front cover (2) by placing your fingers under the front of the cover and pulling upward.

MAINTENANCE AND LUBRICATION

Engine Cooling System

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should need replacement contact your dealer for the correct replacement part.

To insure that the coolant maintains its ability to protect the engine, it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

Using a funnel, slowly add coolant as necessary through the radiator filler neck.

MAINTENANCE AND LUBRICATION

Lubrication

4-Cycle Premium 4 Synthetic Lubricant

CAUTION

Use only Polaris Premium 4 All Season synthetic oil or API certified “SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.

Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° F to 120° F. Its exceptional frictional properties result in more efficient operation, more power output, lower fuel consumption, and easier starting in cold temperatures.

Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable. Oil may need to be changed more frequently if Polaris Premium 4 is not used. You will also need to follow the manufacturers recommendations for ambient temperature operation.

MAINTENANCE AND LUBRICATION

Lubrication

Oil and Filter Change

1. Place vehicle on a level surface.

2. Run engine two to three minutes until warm. Stop engine.

3. Clean area around drain plug.

4. Place a drain pan beneath engine crankcase and remove drain plug. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result.

5. Allow oil to drain completely.

6. Replace sealing washer on drain plug. NOTE: The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14 ft. lbs. (19 Nm).

8. Place shop towels beneath oil filter. Using an oil filter wrench, turn filter counterclockwise to remove.

9. Using a clean dry cloth, clean filter sealing surface on crankcase.

10. Lubricate O-ring on new filter with a film of new engine oil. Check to make sure the O-ring is in good condition.

11. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn and additional 1/2 turn.

12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil.

13. Place gear selector in neutral and set parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

NOTE: Drain Plug Torque: 14 ft. lbs. (19 Nm); Oil Filter Torque: Turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn.

MAINTENANCE AND LUBRICATION

Lubrication

Transmission Lubrication

The transmission fill plug is located on the right side of the machine behind the propshaft shield or footwell.

The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. With the ATV on a level surface, remove fill plug (1) and check the lubricant level. Use the illustration and the chart below to determine the correct fluid level. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN

2871478).

Model

Sportsman 700 1 5/8″ 13.5 (400)

Oil Level “A” Oil Fill Ounces (ml)

Transmission Oil Changing Procedure

1. Remove the four screws on the footwell and gently pull outward for access.

2. Remove fill plug.

3. Remove transmission drain plug (2) located on the bottom left hand side and drain the oil. Catch and discard used oil properly.

4. Clean and reinstall the drain plug torque to 14 ft. lbs. (1.93 kg-m).

5. Add the correct amount of Polaris Premium Synthetic Gearcase Lubricant until oil reaches the bottom of the filler hole.

6. Check for leaks.

7. Reinstall footwell and screws removed in step 1.

Polaris Sprotsman 700 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual