Polaris Sprotsman MV7 User Manual
WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
A card containing important ATV safety information should be attached
to the owner’s manual on the next page. If you cannot locate this card,
or if it has been removed, please call 1-800-342-3764 for assistance.
Copyright 2004 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2005 Sportsman MV7 Owner’s Manual P/N 9919959
2
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational and Utility Vehicles
S Snowmobiles
S All-terrain vehicles (ATVs)
S Watercraft
S RANGER utility vehicles
S Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master S ervice Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride i n our Parts, Apparel and Accessories (PAA)
products, available through our online store at 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.
3
4
TABLE OF CONTENTS
WELCOME 3....................................
VEHICLE IDENTIFICATION NUMBERS 7...........
SAFETY 8......................................
CONTROLS 33..................................
FEATURES 41..................................
OPERATION 49.................................
EMISSION CONTROL SYSTEMS 68...............
MAINTENANCE AND LUBRICATION 69............
ADJUSTMENTS 109.............................
SPECIFICATIONS 112...........................
POLARIS PRODUCTS 114........................
TROUBLESHOOTING 115........................
WARRANTY 119.................................
MAINTENANCE RECORD 124....................
INDEX 127......................................
5
6
VEHICLE IDENTIFICATION NUMBERS
Record your vehicle’s identification numbers and key number 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
one of your existing keys, so if both keys are lost, t he ignition switch
must be replaced.
2
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
Key Number (3):
1
31XX
3
7
SAFETY
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions of the decals carefully. If any of the
decals depicted in this manual differ from the decals on your vehicle,
always read and follow the instructions of the decals on the vehicle.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER operate:
ALW AYS:
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
WARNING
NEVER USE
WITH DRUGS
OR ALCOHOL
7172560
7172561
8
Safety Decals and Locations
WARNING
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 1700 LBS. (771 kg).
This vehicle i s equipped with run-flat tires. In the event of a flat tire, remove all
cargo from the vehicle before riding further. Do not exceed 50 miles (80 km) at
25 MPH (40 km/h). Have the tire inspected by a dealer before further use.
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 pos sible,
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 ov er the side of the
rack.
Read Owner’s Manual for more detailed loading information
7173016
SAFETY
WARNING
ATTENTION
S Operation of this vehicle without the air
filter element will severely damage the
engine.
S Clean pre-filter element often, more
frequent cleaning required in dusty
conditions. Do not operate vehicle
without pre-filter.
S Specific carburetor jetting and
adjustments are required depending
on temperature and altitude. See
your Owner’s Manual.
Factory setting:
40_ to 80_ F . at 0-3000 feet
(5_ to 27_ C. at 0-900 meters).
7172566
7172922
9
SAFETY
Safety Decals and Locations
WARNING
S Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle
with guard removed.
S 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.
NO STEP
7172563
WARNING
WARNING
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.
7172559
S DO NOT TOW FROM RACK OR BUMPER.
Vehicle damage or tipover may r esult causing severe i njur y
or death. Tow only from tow hooks or hitch.
S Max Rack Loads: Front 150 lbs. (68 kg) Rear 300 lbs. (136 kg)
10
7172927
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.
7172564
MANUFACTURED
BY: POLARIS IND. INC.
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT
INTENDEDFOR USE ON PUBLIC ROADS.
CE VÉHICUL E EST UN VÉHICUL E TOUT TERRAIN QUI NiEST
PAS DESTINÉ À ÊTRE UTILIS É SUR LES CHEMINS PUBLICS.
Canadian Certification Decal
ALL WHEEL
DRIVE
SWITCH
Do not push switc h to
engage AWD if the rear
wheels are spinning.
This may cause severe
drive shaft and clutch
damage.
See your Owner’s
Manual.
7079780
7171492
TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG)
7170509
11
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires
special protective clothing for comfort and to reduce the chance 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 that 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 a helmet face shield offer
the best protection for your eyes. They
should be kept clean and be of
shatterproof design (bearing t he
markings Z2.1 or VESC 8).
1
2
3
5
4
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 boots with heels, like
moto-cross boots.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide
the best protection.
12
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in serious injury or death.
A Polaris ATV 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.
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.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of the ATV in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner ’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are t horoughly inspected at specific
intervals.
13
SAFETY
Operator Safety
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.
14
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
S Read this manual and all labels carefully, and follow the operating
procedures described.
S Never operate an ATV without proper instruction. Take a training
course. Beginners should receive training from a certified instructor.
Contact an authorized Polaris A TV dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
S Never allow anyone under 16 years of age to operate this ATV.
S Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safety training course.
S Always avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
S Never operate an ATV on a public street, road or highway, including
a dirt or gravel road.
S Never operate an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.
S Never consume alcohol or drugs before or while operating an ATV.
S Never operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
S Never attempt wheelies, jumps or other stunts.
S Always inspect your ATV before each use to make sure it’ s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
S Always keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation.
S Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in this manu-
al. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
15
SAFETY
Operator Safety
S Always have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
S Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the ter-
rain carefully before ascending a 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 a hill at high speed.
S Always follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a 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 t o one side. Travel straight down the hill when possible.
S Always follow proper procedures for crossing the side of a hill.
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’ve mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.
S Always use proper procedures if you stall or roll backwards while
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. Always dismount
on the uphill side, or to either side if the ATV is pointed straight
uphill. Turn the ATV around and remount following the procedure
described in this manual.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen t rees.
Always follow proper procedures when operating over obstacles as
described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.
S Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
16
SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test the brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operat-
ing in reverse. When it’s safe to proceed in reverse, move slowly
and avoid turning at sharp angles.
S Always use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
S Never modify an ATV through improper installation or use of acces-
sories.
S Never exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY ,call the Consumer Product Safety Commission at 1-800-638-2772, or call
Polaris at 1-800-342-3764.
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris ATV any equipment that may 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
vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
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 vehicle. Use only
Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN
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
Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
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.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN
Severe injury and/or death could occur if a child under the
minimum age recommendation operates an ATV.
Even though a child may be within the recommended age group
for operating some ATVs, he/she may not have the skills,
abilities, or judgment needed to operate an ATV safely and could
be susceptible to accident or injury.
HOW TO AVOID THE
No one under the age of 16 should operate a Polaris ATV.
HAPPEN
HAZARD
18
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on an
ATV.
WHAT CAN
Carrying a passenger
greatly reduces the
operator’s ability to balance
and control the ATV, which
could cause an accident
and injury to the
operator and/or passenger.
HOW TO AVOID THE
Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation. It
is not intended for carrying passengers.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Operating an ATV
on paved
surfaces, including
sidewalks, paths,
parking lots, and
driveways.
WHAT CAN
ATV tires are designed for
off-road use. Operating on
paved surfaces may
seriously affect the handling and
control of the ATV and could result in loss of control, accident,
and/or injury.
HOW TO AVOID THE
Avoid operating the ATV on pavement. If it’s unavoidable, travel
slowly and avoid sudden turns or stops.
HAPPEN
HAZARD
SAFETY
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV on
public streets, roads or
highways.
WHAT CAN
The ATV could collide
with another vehicle.
HOW TO AVOID THE
Never operate the ATV on any
public street, road or highway,
including dirt and gravel roads. In many states
it’s illegal to operate ATVs on public streets, roads and highways.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Operating this ATV without
wearing an approved
helmet, eye protection and
protective clothing.
WHAT CAN
Operating an ATV without
an approved helmet
increases the risk of a
severe head injury or
death in the event of an
accident.
Operating without eye protection could result in an accident and
could increase the chance of a severe injury in the event of an
accident.
HOW TO AVOID THE
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.
HAPPEN
HAZARD
20
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV after consuming
alcohol or drugs.
WHAT CAN
Consumption of alcohol and/or drugs
could seriously affect operator
judgment. Reaction time may be slower
and operator balance and perception
could be affected.
Consuming alcohol and/or drugs before
or while operating an ATV could result in
an accident causing severe injury or death.
HOW TO AVOID THE
Never consume alcohol or drugs before or while operating an
ATV.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Operating the ATV at excessive speeds.
WHAT CAN
Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident.
HOW TO AVOID THE
Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.
HAPPEN
HAZARD
SAFETY
21
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps
and other stunts.
WHAT CAN
Attempting stunts increases
the chance of an accident,
including an overturn.
HOW TO AVOID
HAZARD
Never attempt wheelies,
jumps, or other stunts. Avoid
exhibition driving.
HAPPEN
THE
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE
Always inspect your ATV before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.
HAPPEN
HAZARD
22
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Removing hands from the handlebars or feet from the footrests
during operation.
WHAT CAN
Removing even one hand or foot can reduce ability to control the
vehicle or could cause loss of balance and ejection from the ATV.
If the operator’s foot is not firmly planted on the footrest, it could
come into contact with the rear wheels and lead to accident or
injury.
HOW TO AVOID THE
Always keep both hands on the handlebars and both feet on the
footrests of the ATV during operation.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating
the ATV on unfamiliar
terrain.
WHAT CAN
Unfamiliar terrain may
contain hidden rocks,
bumps, or holes that could
cause loss of control or
overturn.
HOW TO AVOID THE
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
HAPPEN
HAZARD
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating on
excessively rough,
slippery or loose terrain.
WHAT CAN
Operating on excessively
rough, slippery or loose
terrain could cause loss of
traction or loss of control,
which could result in an
accident or overturn.
HOW TO AVOID THE
Do not operate on excessively rough, slippery or loose terrain
until you’ve learned and practiced the skills necessary to control
the ATV on such terrain.
Always use extra caution on rough, slippery or loose terrain.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN
Improper turns could cause loss of control and lead to a collision
or overturn.
HOW TO AVOID THE
Always follow proper procedures for turning as described in the
owner’s manual.
Practice turning at slow speeds before attempting to turn at faster
speeds.
Never turn at excessive speed.
HAPPEN
HAZARD
24
Operator Safety
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN
The vehicle may overturn.
HOW TO AVOID THE
Never operate on hills too steep for the ATV or for your abilities.
Never operate the ATV on hills steeper than 25_.
Practice on smaller hills before attempting large hills.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN
Improper hill climbing could
cause loss of control or
overturn.
HOW TO AVOID
HAZARD
Always follow proper
procedures for climbing
hills as described in the
owner’s manual.
Always check the terrain
carefully before ascending
any hill.
Never operate the ATV on hills steeper than 25_.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly while traveling uphill. 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.
HAPPEN
THE
SAFETY
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Traveling downhill
improperly.
WHAT CAN
Improperly descending a hill
could cause loss of control
or overturn.
HOW TO AVOID
HAZARD
Always follow proper
procedures for traveling
down hills as described in
the owner’s manual. NOTE:
A special technique is
required when braking while
traveling downhill. See page 61.
Always check the terrain carefully before descending a hill.
Shift your weight backward.
Never travel down a hill at high speed.
Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight down the hill
when possible.
HAPPEN
THE
26
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly crossing hills and
turning on hills.
WHAT CAN
Improperly crossing or
turning as hills could cause
loss of control or overturn.
HOW TO AVOID
HAZARD
Neverattempttoturnthe
ATV around on any hill until
you’ve mastered the turning
technique (on level ground)
as described in the owner’s
manual. See page 62. Use
extra caution when turning
on any hill.
Avoid crossing the side of a steep hill.
When crossing the side of a
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.
HAPPEN
THE
hill:
SAFETY
27
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