Polaris 600 manual

Owner's Manual V ehicle Maintenance and Safety 2003 Spor tsman 600 Spor tsman 700 for Read this manual carefully . It contains important safety infor mation. This i s an adult vehicle onl y . Operation is prohibited for those under 16 years of age.[...]

W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductive harm.[...]

1 We’ve creat ed a web si te j ust f or Y OU! S T echnical tips S New product introductions S Event schedules S Parts a nd Service M anual information S Exciting details a bout The W ay Out Ch ec k it out... www . polar isindust ri es.com/ owner[...]

2 All inf or ma ti on i n thi s manua l is bas ed on t he la te s t pr oduc t dat a a nd s pe ci f ic a t ions ava i la bl e a t the t im e of pri nt ing. Pola r is I ndus tr i e s Inc . re s e rve s t he r ight t o make produc t c ha nges a nd impr ove me nts t ha t ma y af f e ct illustration s or ex p lanatio ns. No par t of thi s ma nua l s hal[...]

3 WELC OME Thank you for purcha sing a Polar is vehicle , and welcome to our world-w ide family of Polaris owne rs. W e proudly produce a n exciting line of utility a nd re cr ea tional produc ts. Polaris R ecreational V eh icles S Snowmobiles S All-te rr ain ve hicles ( A TVs) S Pers onal wat ercraft S RANGER utility vehicle s S V i ctory m ot orc[...]

4 VEHICLE IDE NTIFICATION NUMBERS The fra me vehicle ide ntifica tion number (VIN) (1) and engine se rial number (2) a re impor tant for model identific ation whe n registe ring your vehic le, when obtaining insura nce , and when orde ring replacement parts . In t he event your vehicl e is st olen, t hese numbers are esse ntial to the re cover y an[...]

5 TABLE OF CONTENTS WELCOM E 3 ........................................ VEHICLE I DENTIF ICA T ION NUM BERS 4 ............... T ABLE O F CONT ENTS 5 ............................. SAFET Y 6 .......................................... CONTROLS 36 ...................................... FEA T URES 44 ....................................... OPER A TION 5[...]

6 SAFE TY Safety D ecals and Locations W arning decal s have been placed on the A TV for your protection. Read an d foll ow the i nst ructi ons o n each decal careful ly . I f a decal bec omes illegible or c omes of f, contac t your Polar is deale r to purcha se a repl acement . R eplacem ent safety decals are prov ided b y Pol aris at n o charge. [...]

7 SAFE TY Safety D ecals and Locations IMPRO PER TIRE PRESSUR E OR O VERLO ADING can cause loss of contr ol resulting in SEVER E INJURY O R DEA TH. TIR E PRESSUR E IN PSI ( KPa): FRON T 5 (34,5) REAR 5 (34,5) M AXIMUM W EIGHT CAP ACITY (Gross Vehicle Wei ght) INCLUDING MACHINE, DRIV ER AND CARGO IS 1200 LB S. (545 k g). Reduce speed and all ow grea[...]

8 SAFE TY Safety D ecals and Locations Moving par ts haz ard under belt- clutc h guard. T o prev ent ser ious injury, do not operate v ehicle w ith guard remov ed. Do not modify engine or c lutch. Doing so c an caus e part failur e, poss ible imbalance, and ex c ess ive engine RPM w hich c an res ult in serious injury or death. NO STEP 7078689 W AR[...]

9 SAFE TY Safety D ecals and Locations ALL WHEEL DRIVE SWITCH Do not push s witch to engage AW D if t he rear wheels are s pinning. This may cause severe drive shaf t and clutc h damage. See your Owner ’s Manual. 7079780 7079604 7170509 TRAILER MAX WEIGHT : 1500 LBS. ( 682 KG) ON L EVEL GR OUND 850 LBS. ( 386 KG) UP TO 15 ° GRADE HITCH MAX. VERT[...]

10 SAFE TY Safe R iding Gear Always wea r clothing suite d to the t ype of riding. A TV riding requir es specia l protec tive clothing for comf ort and to reduc e t he cha nce of injury . 1. Helmet Y our helmet is the most important pie ce of protec tive gear for sa fe riding. A helm et can preven t a sev ere head i njury . Sel ect an appro ved hel[...]

11 SAFE TY Operator S afety Age Restr ictions This vehicl e is an ADUL T VEHICLE ONL Y . Operat ion is prohi bited for anyone unde r 16 years of age . Know Y our V ehicle As the operator of the vehic le, you are responsible for your pe rsonal safe ty , t he saf ety of others, and the protec tion of our environme nt. Read a nd understa nd your owner[...]

12 SAFE TY Operator S afety The following two pa ges identify signal wor ds and symbols that appe ar in this manual. Y our safety is involve d when these word s and symbols are u sed. Bec ome familia r with their meanings befo re re ading the manua l. The safety aler t sym bol , on your vehicle or in this manual, alert s you to t he potent ial for [...]

13 SAFE TY Operator S afety S Read this ma nual and all labe ls car efully , and fo llow the oper ating proce dures de scribed. S Never ope rate a n A TV without prope r instruction. T ake a training course . Beginners s hould receive training from a certified i nstructor . Co ntact an aut hori zed P olari s A TV deal er or call P olari s at 1-800-[...]

14 SAFE TY Operator S afety S Always hav e the A TV ins pected by an au tho rized P olari s dealer if it’ s been invol ved in an accident. S Neve r operate on hills too steep for the A TV or for your abilitie s. Pra ctic e on smaller h ills befor e atte mpting lar ger hills. S Always fo llow proper pr ocedure s for climbing hills. Check the ter -[...]

15 SAFE TY Operator S afety S W et bra kes may ha ve re duced stopping ability . T est the bra kes af ter lea ving wate r . If ne cessa ry , apply them lightly se vera l times to allow frict ion t o dry out t he pads. S Always chec k for obstacle s or people behind the A TV befor e operat- ing i n reverse. When i t’ s safe t o proceed in rev erse[...]

16 SAFE TY Operator S afety POTENTI AL HAZARD Oper ating this A TV wit hout pr oper inst ruction. WHA T CAN HAPPEN The r isk of an ac cident is great ly increased if t he operator does not know how t o operate t he A T V properly in different sit uations and on differ ent t ypes of t errain. HOW TO A VOID THE HAZ ARD Beginning and inexper ienced op[...]

17 SAFE TY Operator S afety POTENTI AL HAZARD Carry ing a passenger on an A TV . WHA T CAN HAPPEN Carry ing a pass enger greatly r educes the operat or ’s ability t o balance and cont rol the A T V , which c ould cause an accident and injury t o the operat or and/ or passenger. HOW TO A VOID THE HAZ ARD Never c arry a pass enger . The purpos e of[...]

18 SAFE TY Operator S afety POTENTI AL HAZARD Oper ating an A TV on pav ed surf aces, inc luding sidewalks, paths, par king lots, and driv eways. WHA T CAN HAPPEN A T V t ires are designed f or off- road use. Operat ing on paved surf aces may advers ely affect t he handling of t he A T V and could result in loss of contr ol, accident, and/ or injur[...]

19 SAFE TY Operator S afety POTENTI AL HAZARD Oper ating this A TV on public st reet s, roads or highways . WHA T CAN HAPPEN The A T V could collide wit h another v ehicle. HOW TO A VOID THE HAZ ARD Never oper ate the A T V on any public s treet , road or highway , including dirt and grav el roads. In many st ates it ’ s illegal t o operat e A T [...]

20 SAFE TY Operator S afety POTENTI AL HAZARD Oper ating this A TV wit hout wear ing an approved helmet , eye prot ection and prot ect ive clot hing. WHA T CAN HAPPEN Oper ating an A TV wit hout an appr oved helmet inc reases t he risk of a s evere head injury or deat h in the event of an accident . Oper ating without eye pr otect ion could result [...]

21 SAFE TY Operator S afety POTENTI AL HAZARD Oper ating the A T V aft er consum ing alcohol or drugs . WHA T CAN HAPPEN Consumpt ion of alcohol and/ or drugs could ser iously affec t operat or judgment. React ion tim e may be slower and operat or balance and perc eption could be affec ted. Consuming alc ohol and/or drugs befor e or while operat in[...]

22 SAFE TY Operator S afety POTENTI AL HAZARD Att empt ing wheelies, jum ps and other s tunt s. WHA T CAN HAPPEN Att empt ing stunt s incr eases the c hance of an ac cident, including an overt urn. HOW TO A VOID THE HAZ ARD Never att empt wheelies, jumps , or other stunt s. Avoid exhibition driving. W ARNING[...]

23 SAFE TY Operator S afety POTENTI AL HAZARD Failur e to inspect t he A T V befor e operating. Failure t o properly maint ain the A TV . WHA T CAN HAPPEN Poor m aintenance incr eases t he possibilit y of an acc ident or equipment damage. HOW TO A VOID THE HAZ ARD Always ins pect y our A T V bef ore each use t o make sur e it’s in safe oper ating[...]

24 SAFE TY Operator S afety POTENTI AL HAZARD Failur e to use ext ra caut ion when operating t he A TV on unf amiliar terrain . WHA T CAN HAPPEN Unfamiliar t errain ma y contain hidden rocks, bumps, o r holes that could caus e loss of c ontrol or overt urn. HOW TO A VOID THE HAZ ARD T r avel slowly and us e extr a caution when oper ating on unfam i[...]

25 SAFE TY Operator S afety POTENTI AL HAZARD Failur e to use ext ra caut ion when operating on ex cessiv ely rough, slippery or loose t errain. WHA T CAN HAPPEN Operat ing on exces sively r ough, slippery or loos e terrain c ould cause los s of t ract ion or loss of cont rol, whic h could result in an accident or over turn. HOW TO A VOID THE HAZ A[...]

26 SAFE TY Operator S afety POTENTI AL HAZARD T ur ning improperly . WHA T CAN HAPPEN Im proper tur ns could caus e loss of cont rol and lead to a collis ion or overt urn. HOW TO A VOID THE HAZ ARD Always follow pr oper procedures f or turning as descr ibed in the owner ’s manual. Prac tice t urning at s low speeds befor e att empting t o turn at[...]

27 SAFE TY Operator S afety POTENTI AL HAZARD Climbing hills im properly . WHA T CAN HAPPEN Im proper hill climbing c ould cause loss of c ontrol or overt urn. HOW TO A VOID THE HAZ ARD Always f ollow proper procedures f or climbing hills as desc ribed in the owner ’s manual. Always c heck t he terr ain carefully befor e ascending any hill. Never[...]

28 SAFE TY Operator S afety POTENTI AL HAZARD T r aveling downhill improper ly . WHA T CAN HAPPEN Im properly desc ending a hill could cause los s of c ontrol or overt urn. HOW TO A VOID THE HAZ ARD Always f ollow proper procedures f or tr aveling down hills as descr ibed in the owner ’s manual. NOT E: A spec ial technique is requir ed when braki[...]

29 SAFE TY Operator S afety POTENTI AL HAZARD Impr operly cr ossing hills and t urning on hills. WHA T CAN HAPPEN Impr operly cr ossing or t urning as hills could caus e loss of c ontrol or overt urn. HOW TO A VOID THE HAZ ARD Never at tempt t o turn t he A T V around on any hill unt il you’ve mast ered the t urning t echnique (on level gr ound) [...]

30 SAFE TY Operator S afety POTENTI AL HAZARD Stalling, r olling backwards or improper ly dismount ing while climbing a hill. WHA T CAN HAPPEN The v ehicle could overt urn. HOW TO A VOID THE HAZA RD Maint ain steady s peed when climbing a hill. If all f orward speed is lost: Keep your weight uphill. Apply t he brakes. Lock t he parking brak e when [...]

31 SAFE TY Operator S afety POTENTI AL HAZARD Im properly operat ing over obs tacles . WHA T CAN HAPPEN Oper ating over obs tacles could caus e loss of cont rol or over turn. HOW TO A VOID THE HAZ ARD Befor e operating in a new ar ea, chec k for obst acles. Avoid operating ov er large obst acles suc h as rock s and fallen tr ees when possible. If u[...]

32 SAFE TY Operator S afety POTENTI AL HAZARD Oper ating the A T V thr ough deep or fast -f lowing water . WHA T CAN HAPPEN T i res may float , caus ing loss of trac tion and loss of cont rol, which could lead t o an accident or over turn. HOW TO A VOID THE HAZ ARD Avoid operating t he A T V thr ough deep or fas t-f lowing water. If it’s unavoida[...]

33 SAFE TY Operator S afety POTENTI AL HAZARD Oper ating this A TV wit h improper t ires, or wit h improper or uneven tire pressu re. WHA T CAN HAPPEN Use of i mproper t ires, or operat ion of t he A T V with im proper or uneven t ire pressur e, could c ause loss of cont rol or ac cident. HOW TO A VOID THE HAZ ARD Always us e the siz e and type of [...]

34 SAFE TY Operator S afety POTENTI AL HAZARD Over loading the A TV or car rying/ towing cargo im properly . WHA T CAN HAPPEN Over loading and towing can c ause changes in v ehicle handling, which could lead t o loss of cont rol or an acc ident. HOW TO A VOID THE HAZ ARD Never ex ceed the st ated load c apacity f or t his A T V . Cargo should be pr[...]

35 SAFE TY Operator S afety Oper ating a damaged A TV can res ult in an acc ident wit h serious injury or death. Af ter any overt urn or ac cident, have a qualif ied serv ice dealer inspect t he entire m achine for possible dam age, including (but not limit ed to) brak es, t hrott le and st eering systems. Safe oper ation of this rider- activ e veh[...]

36 CONTROLS Engine E lectrical S witches Overri de S wit ch (1) (Rever se Speed Limiter ) - This vehicle is equippe d with a r ever se speed limite r system. T o gain a dditional powe r while backing, depre s s the override switc h. NOTE: The overr ide switch a lso allows ac tivation of D emand 4 Dr ive (A ll Whee l Drive) in reve rse, if the A WD [...]

37 CONTROLS Throttle Lever Eng ine sp eed and vehi cle moveme nt are contr olled by pressing the throttle le ver (1) . The throttle le ver is spring load ed. Eng ine s peed ret urns to idle when the lev er is releas ed. This A TV is equipped w ith Polar is Elec tronic T hrottle Contr ol (ETC) , which is de signed to re duce the risk of a f roze n o[...]

38 CONTROLS Light Sw itches The light switch is loca ted on the le ft handle bar . It’ s used to turn the lights on and of f and to switch the lights from HI to LO. NOTE: The lights won’ t work unless the key is in the on position and the shut-of f s w i t c hi si nt h e run position. Br ake Lever The fro nt and rear brak es are app lied by s q[...]

39 CONTROLS Master Cylinder The brake f l uid in the master cylinde r (1) , which is loca ted on the left handle bar , should be chec ked before each ride. Th e flui d level can be seen thr ough an indicator window (2) on the top of the master cylinde r . This eye wil l app ear dark whe n the fluid le vel is full. When fluid needs to be added, the [...]

40 CONTROLS Park in g Brake Setting the Par king Brake 1. Sq ueeze and r elease t he brak e leve r (1) two or thre e times, then squ eeze and h old. 2. Push the p ark br ake loc k (2) forwa rd t o engage the br ake. Rel ease th e brake l ever . 3. T o release the par king brake lo ck, s queeze an d releas e the b rake leve r . It will return to its[...]

41 CONTROLS Auxiliary Brake Y our Polaris A TV ha s an auxiliar y brake (1) for a dded safe ty . It’ s locate d on the inside of the right floor board and is oper ated by the right foot. The auxilia ry brake serves as a b ackup t o t he mai n brak e system if the main system bec omes inoperative . If the re ar whee ls slide while using the auxili[...]

42 CONTROLS Choke The choke assists in starting a co ld engine. Refe r to the engine starting proce dure on page 53 for corre ct choke and throttle settings during starting. Fuel V alve The fu el val ve (1) i s lo cated o n the l eft s ide panel. It has three positions: OFF: F or vehic le storage and when tra nsporting. ON: For normal operation. RE[...]

43 CONTROLS Automatic T r ansmission Gear Selector The tra nsmission gear selec tor is located on the right side of the vehicle dir ectly above and for ward of the engine. It ha s five positions: high (H), low ( L), neut ral (N), revers e (R) and park (P). T o shift into high or park , you m ust fi rst depres s the auxiliar y brake to activate the [...]

44 FEATURES All Wheel D rive (A WD) S ystem Pol aris 4-wh eel drive A TVs are equipped w ith a unique, Po laris -exclu sive, Dem and 4 Driv e (A WD) sy stem act ivat ed by a swit ch (1) on the right handlebar . When the switch is of f, the A TV is in 2 whe el drive at a ll times. Whe n the switch is on, the A TV is in Dema nd 4 Drive and the A WD i[...]

45 FEATURES In stru ment Cl ust er Y our A TV is e quipped with an instrume nt cluster that sense s vehicle speed from the r ight front whe el. The instrume nt cluster mea sures distanc e in miles a s well as hours of opera tion. It also include s a reve rse spee d limiter f unction that limits the A TV’ s speed to approxima tely 7-9 mph. Refer t[...]

46 FEATURES In stru ment Cl ust er Ride r Infor mati on Center The r ider inf ormation c enter is loca ted in the low er por tion of the instrume nt cluster . 1. Ge ar Indic ator - As the shift lever is move d, this will indicate the gea r the mach ine i s in : H = High Range L = Low Range N = Neutral R = Reverse P=P a r k Eo rb l a n k= E r r o r-[...]

47 FEATURES In stru ment Cl ust er Ride r Infor mati on Center The r ider inf ormation c enter ha s 4 standa rd modes: Mode 1 - Odometer Mode 2 - T ripmeter Mode 3 - T otal S ervic e Hours Mode 4 - Programma ble servic e interval The reve rse override button on the left handleba r is also the mode button . NOTE: I f using the mode button to program[...]

48 FEATURES In stru ment Cl ust er Ride r Infor mati on Center Mo de 4 - Prog rammab le Service Int erval The purpose of the progra mmable servic e interva l is to provide the consumer a nd dealer with a conve nient reminde r for routine maintena nce. When your vehicle le aves the fa ctory , this featur e is turned of f. Y ou must enable the progra[...]

49 FEATURES In stru ment Cl ust er Ride r Infor mati on Center Diagnos tic Mode The diagnostic mode is for infor mational purpose s only . Please re turn your A TV to your dea ler for a ll major re pairs. T o enter the diagnostic s mode: 1. T urn the key switc h off a nd wait 20 seconds. 2. Se t the park br ake and shift the tr ansmission to ne utr[...]

50 OPERATION Fuel Safety Gasoline is highly f lammable and explos ive under cer tain conditi ons. S Always exerc ise extr eme caut ion whenever handling gasoline. S Always ref uel with the engine s topped, and outdoor s or in a well vent ilated area. S Do not sm oke or allow open f lames or s parks in or near t he area where r efueling is perf orme[...]

51 OPERATION Br eak-In Period The bre ak-in period f or your new Polaris A TV is define d as the first ten hours of opera tion, or the time it takes to use the first two full tanks of gasoline. No single a ction on your part is as impor tant as f ollowing the proce dures for a proper bre ak-in. Care ful treatme nt of a new engine will result in mor[...]

52 OPERATION Pr e-Ride Inspection Use the fo llowing chec klist to verify tha t your vehic le is in proper working c ondition before each use. Item/Inspection Procedure 1. T ires - Chec k condition and pressur es. 2. Fue l tank and e ngine oil level - Fill both to their prope r leve ls. 3. All br akes - Check ope ration, ad justment and f luid leve[...]

53 OPERATION Star ting the E ngine Sta rti ng a Col d Engine 1. Plac e the transmission in neutral and lock the pa rking brake. 2. T urn the fuel tank valve on. 3. Sit on the vehicle and pull the choke knob out until it stops (1). NOTE: The va riable c hoke is fully on when the knob is pulle d comple tely out. The choke is of f when the knob is pus[...]

54 OPERATION Star ting the E ngine Sta rti ng a W ar m Engi ne W arm engine s do not normally re quire the use of the choke . Using the choke ca n cause the spark plug to become we t fouled. 1. Position the vehic le on a level surfac e with the transmission in neutra l. 2. Loc k the parking bra ke, turn the fue l tank valve on, sit on t he vehicle [...]

55 OPERATION Hauling Cargo Y our A TV has be en designe d to car ry or tow a ce rtain a mount of load. Always re ad an d understa nd the load distr ibution war ning labels on the vehi cle, and n ever exceed th e weigh t capac ities spec ified in your owner ’ s m anual and o n safety d ecals. Car go weight should be eve nly distributed (1/3 on the[...]

56 OPERATION Hauling Cargo Hauling cargo im properly can alt er vehic le handling and may caus e loss of cont rol or brake inst ability and res ult in serious injury or death. Always follow t hese precaut ions when hauling car go: S REDUCE SPEED AND ALLOW GREA TER DI ST ANCES FO R BRAKING WHEN H AULING CAR G O. S CARGO W EIG HT DI STRI BUT ION s ho[...]

57 OPERATION Driving Safely Driving Pr ocedures 1. Sit upright with both fe et on the footr ests and both hands on the handleba rs. 2. Star t the engine and a llow it to warm up, then shif t the tran smission into gea r . 3. Che ck your sur roundings and de termine your path of tr avel. 4. Re lease the par king brake. 5. Slowly de press the thr ott[...]

58 OPERATION Driving Safely Making T urns Y our A TV is e quipped with a solid rea r axle, which dr ives both rear whee ls equally at a ll times. This means tha t the whe el on the outside of t he tur n mus t t ravel a g reater di stan ce than th e ins ide wh eel when turning a nd the inside tir e must slip tra ction slightly . T o turn, steer in t[...]

59 OPERATION Driving Safely Driving on Slippery S u rfaces Whenev er ridin g on sl ipp ery surfaces su ch as wet trai ls or l oose grav el, or duri ng freezin g weather , fol low t hese precau tio ns: 1. Slow down whe n enter ing s lipper y are as. 2. Mai ntai n a high l evel of al ertnes s, readi ng t he trail and av oid ing qui ck, s harp turn s,[...]

60 OPERATION Driving Safely T raveling Uphill Whe neve r trav eling uphill, follow these pr ecauti ons : 1. A lways tr ave l straight uphill. 2. A void steep hills ( 25 _ maximum) . 3. Ke ep both feet on the f ootrests. 4. T ransfer your we ight forwar d. 5. Pro ceed at a stead y rate of speed an d thr o ttle opening. 6. Re main ale rt and be pre p[...]

61 OPERATION Driving Safely Sidehilling Sidehilling can be a dange rous type of driving and should be avoide d if at all possible. If you do ente r into a situa tion wher e sidehilling is necess ary , fo llo w thes e precaut ion s: 1. Slow down. 2. Le an into the hill, transfe rring your upper body w eight towa rd the hill while keeping your fee t [...]

62 OPERATION Driving Safely T raveling Downh ill Whe neve r desce nding a hill, follow these pr ecauti ons : 1. Pro ceed direct ly do wnh ill. 2. T ransfe r your weight to the rea r of the vehicle. 3. Slow down. 4. Apply the brake s slightly t oa i di ns l o w i n g . Familiar ize yourse lf with operation of the auxilia ry brak e in the event los s[...]

63 OPERATION Driving Safely T urning A round on a Hill If the ve hicle sta lls while climbing a hill, never bac k it down the hill! One mane uver tha t can be use d when it’ s necessa ry to turn a round while c limbing a hill is the K-turn: 1. Stop and loc k the par king brake while ke eping body weight uphill. 2. Le ave the tra nsmission in forw[...]

64 OPERATION Driving Safely Dr iving Through W ater Y our A TV can ope rate through wa ter with a maximum rec ommended depth equa l to the bottom of the footre sts (1). Follow thes e procedu res when opera ting through water: 1. D etermine wa t er depths and c urre nt befor e crossing. 2. Choose a c rossing where both banks have gr adual inclines. [...]

65 OPERATION Driving Safely Driving Over Obstacles Be alert ! Loo k ahead and l earn to read th e terrain yo u’re travel ing o n. Be con stan tly al ert for hazard s such as l ogs , rocks and l ow hang ing branch es. Severe injur y or deat h can result if your v ehicle comes in cont act with a hidden obst acle. Not all obst acles ar e immediately[...]

66 OPERATION Driving Safely Driving in Rever se Fo llo w these precau tio ns when op eratin g in revers e: 1. Alwa ys avoid bac king downhill. 2. Ba ck slowly . 3. When in rev erse, apply the brake s lightly for stopping. 4. A void turning at sharp angles in r everse. 5. N ever ope n t he throttle suddenly while bac king. NOTE: Most Polaris A TVs a[...]

67 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible. If it’ s unavoidable, follow thes e precaut ion s: 1. T urn the engine of f. 2. Plac e the transmission in park. 3. Set the parking bra ke. 4. Alwa ys block the rear whee l s on the downhill side. See illustration. 5. Shut of f the fue l supply[...]

68 NOISE EMISS ION CO NTROL SYSTEM R EGUL ATI ON T AMP ERING WITH NOISE C ONTROL S YSTEM P ROHIBITED! U.S. Federa l law prohibits the following acts or the causing there of: (1) The remova l or rende ring inoperative by a ny person other than f or purp oses of m aint enance, rep air , or rep lacem ent of an y devi ce or eleme nt of design incor por[...]

69 MAINTENANCE AND LUBRICATION Accessor ies Auxiliar y power outlets provide 12V pow er for ope rating access ories such as ha nd held spot lights. Acc essory outlets ar e ava ilable for a ll models. Contact your Polaris dea l er f or more infor mation. Pol aris has a wi de range of additi onal accesso ries avail able for your A TV . See your Polar[...]

70 MAINTENANCE AND LUBRICATION Per iodic Maintenance S chedule Hours of ope ration a re ba sed on a 10 mph a verage. If se rvice is due a t 20 hours, the equiva lent odometer re ading would be 200 miles. Perfo rm all servi ces at which ever reading i s reached first . Item Hours/ Mile s Frequency Remar ks Brake Syst em Pre- Ride Pre-Ri de Inspect A[...]

71 MAINTENANCE AND LUBRICATION Per iodic Maintenance S chedule Item Hours/ Mile s Frequency Remar ks " Air box sediment tube Pr e-Ride Pre- Ride Drain deposi ts whenever visi ble Headlamp Pr e-Ride Pr e-Ri de Check operat ion daily; ap- ply Pol aris di elect ri c grease to connect or when repl aced T ail la mp /brak e lam p Pr e-Ri de Pre- Rid[...]

72 MAINTENANCE AND LUBRICATION Per iodic Maintenance S chedule Item Hours/ Mile s Frequency Remar ks Carbur etor fl oat bowl 50 hrs. 6 months Drai n bowl periodi cally and pri or to s t orage J Throt tle Cabl e/ETC Swit ch 50 hrs. 6 months Inspect; adj ust; l ubri cate; repl ace if necessar y L Choke (enr icher) cable 50 hr s. 6 months Inspect ; ad[...]

73 MAINTENANCE AND LUBRICATION Per iodic Maintenance S chedule Item Hours/ Mile s Frequency Remar ks " Rear axle 50 hrs. 6 months Inspect bear ings; lube J L Igni tion T iming 100 hrs. 12 months Inspect ; adjust as needed J L Fuel system 100 hours 12 m onths Check for leaks at t ank cap, li nes, fuel valve, fi lter , pump and carbur etor; re- [...]

74 MAINTENANCE AND LUBRICATION Per iodic Maintenance Recor d Use th e foll owin g chart to reco rd peri odic m aint enance. Maintenance In terval Perfo rmed Ser vicing Date Ser vicing Dealer or Pe rs on Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.[...]

75 -N O T E S -[...]

76 MAINTENANCE AND LUBRICATION Lubricati on Recomm endations NOTE: Hours a re based on 10 mph ave rage. If ser vice is due at 20 hours, the equiva lent odometer re ading would be 200 miles. Perf orm all s ervices at whi chever readi ng is reach ed first . Lubri cati on Char t Key " More of ten under sever e use, such as we t or dusty condition[...]

77 MAINTENANCE AND LUBRICATION Lubricati on Recomm endations (4) (1) (5) (2) (3) (6)[...]

78 MAINTENANCE AND LUBRICATION Lubricati on Recomm endations Pr emium 4 Syntheti c Lubri cant Polaris Pre mium 4 All Season synthetic engine oil ha s been spe cially formula ted for use in Polaris 4-cyc le engines. It’ s a fully synthetic, high perf ormance , multi-viscosity oil designe d to provide the ultima te in l ubri catio n performan ce an[...]

79 MAINTENANCE AND LUBRICATION Lubricati on Recomm endations Engi ne Oil C heck The oil dipstick and fill tube are loca ted on the left side of the vehicle. 1. Position the A TV on a level surface. 2. Star t t he engine a nd let it idle for 20-30 sec onds. 3. Stop the engine and lift the lever loc k (1) on the dipstick. Remove the dipstic k and wip[...]

80 MAINTENANCE AND LUBRICATION Lubricati on Recomm endations Oil and F ilter Change 1. Pl ace the v ehicl e on a l evel s urface. 2. Run the e ngine for two to three minutes until warm. Stop the engine. 3. Clea n the area ar ound the drain plug. 4. Plac e a drain pan benea th engine cra nkcase and remove the dr ain plug. 5. A llow the oil to drain [...]

81 MAINTENANCE AND LUBRICATION Lubricati on Recomm endations T ransmission Oil Check The tra nsmission oil fill plug (1) is locate d on the right side of the mac hine behind the footwe ll. The tran smission oil level should be chec ked ever y six months or 1000 miles (1600 km), whiche ver c omes first. T ransmission oil should be change d annually [...]

82 MAINTENANCE AND LUBRICATION Lubricati on Recomm endations Front Gearcase Oil Check The fr ont gear case lubrica nt level should be c heck ed eve ry six months or 1000 miles ( 1600 km), whiche ver c omes first. Front gearc ase oil should be cha nged annually . 1. Position the A TV on a level surf ace. 2. Re move the f ill plug (1) a nd chec k the[...]

83 MAINTENANCE AND LUBRICATION Lubricati on Recomm endations Rear Gearcase Oil Check W it h t he A TV on a l evel surface, rem ove t he fil l p lug an d vi sual ly inspect the lubric ant level through the fill hole (1). Maintain the oil leve l with the bottom o f the f ill plug hole. Rear Gearcase Oil Change 1. Re move the dra in plug (2). C atc h [...]

84 MAINTENANCE AND LUBRICATION Engine Cool ing System Coolant Level The r ecove ry bottle (1) is loca ted on the left si de of t he mach ine. T o acces s th e rec overy bottle, remove the left side pane l as outlined on pa ge 93. The fluid level must be maintained betwe en the minimum and maximum marks on the bottle (whe n the fluid is cool). The e[...]

85 MAINTENANCE AND LUBRICATION Engine Cool ing System Radiator Coolant Level NOTE: This proc edure is re quired only if the cooling syste m has bee n draine d for mainte nance a nd/or repair . Howe ver , if the rec overy bottle has run dry , t he leve l in the radiator should be inspec ted and c oolant added if n ecessary . 1. Using the tool provid[...]

86 MAINTENANCE AND LUBRICATION Adjus tments Front B rake The front brake s are hydr aulic disc bra kes. They’re ac tivated by moving the brake leve r toward the handlebar . These brakes ar e self- adjusting. The fo llo wing ch ecks are reco mmen ded to keep the b rake sy stem in good opera ting condition. Check more of ten if brake s are used hea[...]

87 MAINTENANCE AND LUBRICATION Adjus tments Rear Br ake The rea r brake is a hydraulic disc bra ke and is acti vated by th e same l ever t hat act ivat es the front brak e system. The rea r brake system is self -adjusting a nd requires no maintena nce other than per iodic chec ks of the p ads fo r wear . Pads should be cha nged whe n worn to 3/64 ?[...]

88 MAINTENANCE AND LUBRICATION Adjus tments T oe Alignm ent Use the following proce dure to check the toe alignme nt of the vehicle. The rec ommended toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set the handleba rs in a straight- ahead position. NOTE: The steeri ng fro g can be used as an i ndi cato r of whether the handle bars are straight. The[...]

89 MAINTENANCE AND LUBRICATION Adjus tments Steering Assem bly The stee ring assembly of the A TV should be che cked pe riodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris deale r for ser vice bef ore oper ating the vehicle . Camber and Caster The cambe r and caster a re non-a djustable . Rear Spr ing The rea r [...]

90 MAINTENANCE AND LUBRICATION Adjus tments Handlebars The h andleb ars can b e adju sted for rider p reference. 1. Locat e handl ebar bo lts (1) b y removing the upper he adlight pod. 2. Loose n the four bolts. 3. A djust the handleba r to the desired height. Be sure the handleba rs do not contac t the gas ta nk or any other pa rt of the mac hine [...]

91 MAINTENANCE AND LUBRICATION Adjus tments Car buretor /Idle RP M If the engine idle spe ed is not satisfa ctory , and all other conditions are f avorable, the car buretor can be ad jus ted. 1. W a rm up the engine by running the vehicle for appr oximately five minutes. 2. Pla ce the tra nsmission in gear with the parking bra ke applied. 3. A djus[...]

92 MAINTENANCE AND LUBRICATION Adjus tments Throttl e Cabl e Free play Throttle c able fre epla y is adjusted at the handleba r . 1. Slide the boots (1) of f the inline cable adjuste r sleeve ( 2). Loosen the adjuster loc knut (3). 2. T urn the adjuster until 1/16 ″ to 1/8 ″ freeplay i s achiev ed at the th umb l ever . NOTE: Wh ile adjusting f[...]

93 MAINTENANCE AND LUBRICATION Adjus tments Si de Pane l Rem oval NOTE: Side pa nel re moval may be dif ficult until the locking tabs a nd receivers hav e been snapp ed and uns napped a few times. 1. Re move the seat. 2. Gr asp the rear of the side panel near t he rear cab. W i th a quick a nd firm motion, pull the pan el forward and ou tward to di[...]

94 MAINTENANCE AND LUBRICATION Adjus tments Tir e T read Depth Always rep lace tires wh en tread depth is worn to 1/8 ″ ( . 3 cm) or less. See illustr ation. Wheel Rem oval 1. Stop the e ngine, place the tr ansmission in gea r and lock the parking br ake. 2. Loose n the wheel nuts slightly . 3. Ele vate the side of the vehicle by placing a suitab[...]

95 MAINTENANCE AND LUBRICATION Adjus tments Wheel Installation 1. Plac e the transmission in gear and lock the pa rking brake. 2. Apply a small amount of red L octite t (provide d with your A TV) to the studs if the nuts are re gular nuts. Do not apply Loc tite t if th e nuts hav e an att ached washer . 3. Pl ace the w heel o n th e wheel h ub wi t[...]

96 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service 1. Rem ove t he seat , rel ease t he cli ps, and remove the a ir box cover . 2. Loose n the clamp an d remove the filte r . 3. Re move the fabric type pre -filte r (1) f rom the main filte r (2). W a sh the pre -filter in soa py water , then rinse and let dry . 4. Re install the pre-[...]

97 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a halogen lamp, don’ t touch the la mp with bare finger s. Oil from your skin leave s a r esidue, c ausing a hot spot that will shorten the life of the la mp. Headlight Lamp Replacement 1. Remove the two scr ews on the lower front corners of the headlight pod. 2. Usin g a small fl at-bl ade s[...]

98 MAINTENANCE AND LUBRICATION Lights High Beam Ad justmen t The he adlight beam ca n be adjusted to a ny position desire d by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehic le on a level surfac e with the headlight approxima tely 25 ft. (7.6 m) from a w all. 2. Me asure the distance f rom the floor [...]

99 MAINTENANCE AND LUBRICATION Lights Headlight Housin g Replacement 1. Remove the two scr ews on the lower front corners of the headlight pod. 2. Usin g a small fl at-bl ade screwdri ver , p ush i n on the l ock tab through the two small openings at the front of the hea dlight pod. 3. Lif t the pod slightly while depressing the tabs. 4. Re move th[...]

100 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Rem o val / Installation 1. T urn the bac k of the headlight ha rness ( 1) in a clockwise dir ection. 2. Pull the harne ss asse mbly out fro m the hea dlight asse mbly . 3. Re move the headla mp and rep lac e with a new he adla mp. 4. Inst all t he new headl amp and h arness as semb ly into the [...]

101 MAINTENANCE AND LUBRICATION Spa rk P lugs S Use RC 7YC sp ark plugs. S Proper ele ctrode gap is .035 ″ (.90 mm). S Spark plug torque is 14 ft. lbs. (19 Nm). Spark plug c ondition is indicative of engine opera tion. The spa rk plug firing end c ondition should be read a fter the engine has be en wa rmed up and t he vehi cle has been d riven at[...]

102 MAINTENANCE AND LUBRICATION V eh ic le Imme rsio n If it’ s impossible to t ak e your A TV to a dea ler bef ore sta rting it, follow the steps outlined below . 1. Move the A TV to dry land or at the very lea st, to water be low the footre sts. 2. Che ck the a irbox for any wate r and dry it if wate r is prese nt. Filter replacem ent is requ i[...]

103 MAINTENANCE AND LUBRICATION Spar k Arr estor Use th e foll owin g proced ure to p eriod icall y purge accum ulat ed carbon from the exhaust pipe /muffle r . 1. Re move the arr estor clea n-out plug (1) fr om the bottom of t he muf fler . 2. Plac e the transmission in neutral and star t the engine. 3. Pur ge carbon fr om the system by momenta ri[...]

104 MAINTENANCE AND LUBRICATION PV T System The basic oper ation of t he Polaris PVT system is dependent on engine speed and vehi cle to rque req uirem ents . As en gin e speed i ncreases , t he forc e exer ted on the movable drive sheave by the flyweights also incre ases. This, in tur n, incre ase s the amount of pinc h a p p l i e dt ot h e drive[...]

105 MAINTENANCE AND LUBRICATION PV T System PVT Dryin g There may b e some in stan ces when water i s acciden tly i nges ted in to the PVT system. Use the following instructions to dry it out before opera ting: 1. Re move the drain plug and allow the wate r to drain. Replac e the drain plug. 2. Star t the engine and shift the transmission into neut[...]

106 MAINTENANCE AND LUBRICATION Batter y Kee p the battery te rminals and conne ctions free of cor rosion. If clea ning is necessa ry , remove the cor rosion with a stiff wir e brush. W ash with a solution of one table spoon baking soda a nd one cup wate r . Ri nse wel l wit h tap water an d dry off with cl ean shop t owels . C oat t he ter minals [...]

107 MAINTENANCE AND LUBRICATION Batter y Batt ery Removal 1. Re move the strap secur ing the battery . 2. Re move the batte ry vent tube from the batter y . 3. Disco nnect the b lack (n egati ve) bat tery cabl e first . 4. D isconnec t the red (positive ) battery cab le next. 5. Lif t the ba ttery out of the A TV , being care ful not to tip it side[...]

108 MAINTENANCE AND LUBRICATION Batter y Battery Installation and Conn ections 1. Se t the batte ry in the ba ttery holder . 2. I nstall the ba ttery vent tube . NOTE: It m ust be free of obstructions a nd secure ly installed. If not, batter y gases could accumul ate and cause an expl os ion. The tube s hould be routed awa y from the f rame and bod[...]

109 MAINTENANCE AND LUBRICATION Cleaning and S torage See page 1 17 for the part numbers of Polaris-r ecomme nded products. Cleaning the A TV Keep ing your A T V cle an will not only improve its a ppear anc e but it ca n also exte nd the life of va rious components. W ith a few precautions , your A TV can be cleaned m uch like an automobi le. W ash[...]

11 0 MAINTENANCE AND LUBRICATION Cleaning and S torage See page 1 17 for the part numbers of Polaris-r ecomme nded products. Sto rag e Tips Clean t he Exterior Make ne cessary r epairs and the n clean the A TV thoroughly with mild soap an d war m water to remove all dirt and gr ime. Don’t use harsh deter gents or high pressure wa shers. S ome det[...]

111 MAINTENANCE AND LUBRICATION Cleaning and S torage See page 1 17 for the part numbers of Polaris-r ecomme nded products. Sto rag e Tips Fog the Engi ne 1. Remove the spark plug a nd add 2-3 ta blespoons of Pre mium 4 Sy nth etic 0 W40 en gine o il . T o access the p lug hol e, us e a sect ion of clear 1 /4” h ose and a smal l p last ic sq ueez[...]

11 2 MAINTENANCE AND LUBRICATION Cleaning and S torage See page 1 17 for the part numbers of Polaris-r ecomme nded products. Sto rag e Tips Batte ry Mai ntena nce Remove the batte ry and add distille d water to the prope r leve l . Do not use tap water , w hich m ay cont ain mi nerals t hat red uce batt ery life. Appl y di electri c grease t o th e[...]

11 3 TROUBLE SHOOTIN G Drive Belt and Cover Problems Po ssibl e Cause Soluti on Dri ving t he A TV ont o a pick up o r tall trailer in high r ange . Shif t tr ans mis si on to l ow range duri ng loa ding of the A TV to pre vent be lt bur ning. Sta rti ng out going up a steep inclin e. Whe n sta rti ng out on an i ncl ine , use low ra nge or dis - m[...]

11 4 TROUBLE SHOOTIN G Contact your Polaris dea ler for se rvice if you’ re unable to identify solutions using the following c harts. Engine Doesn’t T urn Over Possi ble Ca use Sol ution Tripp ed circu it b reaker Reset th e b reaker Lo w battery vo ltag e Rec har ge ba tte ry to 12. 5 VDC Loose ba tte ry conne ct ions Ch eck all conn ectio ns [...]

11 5 TROUBLE SHOOTIN G Engine Backfires Possi ble Ca use Sol ution W ea k spa rk f rom s park pl ugs Insp ect, clean and /or replace spark p lug s Inco rrect spark p lug g ap or heat rang e Set gap t o spec s or re pla ce plugs Old or non-r ec omme nded fue l Repl ace w it h new fue l Inco rrectly installed sp ark pl ug wi res See your Pola ri s de[...]

11 6 TROUBLE SHOOTIN G Engi ne Stops or Loses Pow er Possi ble Ca use Sol ution Out of fuel Turn fu el valv e to reserv e, refuel Kinke d or plugged fue l vent li ne Insp ect an d rep lace W ater p resen t in fu el Repl ace w it h new fue l Ove rus e of choke Insp ect, clean and /or replace spark p lug s Foule d or de fe cti ve s par k plugs Insp e[...]

11 7 POLARIS RECOMMENDED PRODUCTS Part No. Descri ption Engine Lubr icant 2870791 Fogging Oi l (12 oz. Aerosol ) 2871721 Polar is Premi um Gold Synthet ic 2-Cycl e Oil (qt .) 2871240 Polar is Premi um Gold Synthet ic 2-Cycl e Oil (2. 5 gal. ) 2872927 VES Syntheti c 2-Cycle Oi l (qt .) 2871098 Premi um 2 Cycle Engine O il (qt. ) 2871281 Engine Oi l [...]

11 8 SPECIFICA TION S SPORT SMAN 600 Gro ss V ehicle W eig ht 1240 lbs /563kgs Fu el Cap acity 4.7 5 gallo ns/1 7.9 8 liters T owing Ca pac ity 1500 lbs /681 kgs Hit ch T ongue Capa cit y 15 0 lb s/68 .1 kg s (Rear rack capacity and tongue w ei ght not to ex ceed 20 0 lbs/9 0. 7 kg s) Fro n t Rack C apacity 100 l bs/ 45.4 kgs Rear R ack C apacity 2[...]

11 9 SPECIFICA TION S SPORT SMAN 600 Shif t T ype Side Le ver (Hig h, L ow, Neutral, R everse, P ark) Gear R edu ction - L ow 7.5/ 1 Gea r Reduc ti on - Reve rs e 5.1 1/1 Gea r Reduc tion - High 3.09/ 1 Driv e Ratio - F ron t: 3.82/ 1 Driv e Ratio - F inal 3. 10/1 Tire Size - F ron t 2 5x8-1 2 Tire Size - R ear 2 5x1 1-1 2 Front Br ake Hydra ulic D[...]

120 SPECIFICA TION S SPORT SMAN 700 Gro ss V ehicle W eig ht 1240 lbs /563kgs Fu el Cap acity 4 .7 5 gallon s/17 .9 8 liters T owing Ca pac ity 1500 lbs /681 kgs Fro n t Rack C apacity 100 l bs/ 45.4 kgs Rear R ack C apacity 200 lbs /90.7 kgs Hit ch T ongue Capa cit y 15 0 lb s/68 .1 kg s (Rear rack capacity and tongue w ei ght not to ex ceed 20 0 [...]

121 SPECIFICA TION S SPORT SMAN 700 Shif t T ype Side Le ver (Hig h, L ow, Neutral, R everse, P ark) Gear R edu ction - L ow 7.5/ 1 Gea r Reduc ti on - Reve rs e 5.1 1/1 Gea r Reduc tion - High 2.89/ 1 Driv e Ratio - F ron t: 3.82/ 1 Driv e Ratio - F inal 3. 10/1 Tire Size - F ron t 2 5x8-1 2 Tire Size - R ear 2 5x1 1-1 2 Front Br ake Hydra ulic Di[...]

122 WARRANTY LIM ITED W ARRANT Y Polaris I ndustries Inc., 2100 Highway 55, Medina, MN 55340, give s a SIX MONTH LIMITED W ARR ANTY on all components of the Po laris Al l T errai n V ehicle (A TV) agains t defects i n materi al or workma nship. Polar is also gives a one year limite d warra nty on the final drive cha in for failure due to def ects. [...]

123 WARRANTY W ARRANT Y COVERAGE AND EXCLUSIONS: LIM IT A T IONS OF W ARRANTIES AND REM EDIES The Polar is limited warr anty exclude s any fa ilures that ar e not ca used by a def ect in materia l or workma nship. This warranty doe s not cover accid ental dam age, n ormal wear an d tear , ab use o r imp roper han dli ng. This warr anty also doe s n[...]

124 WARRANTY ALL IMPLIED W ARR ANTIES (INCLUDING B UT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MER CHANT AB ILITY AND FITNES S FOR A P AR TICULAR PUR POSE) AR E LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARR ANTY PER IOD. POLARIS F UR THER DIS CLAIMS ALL EXPRES S W ARRANTIES NOT ST A TED IN THIS W ARRANTY . So me stat es do not all ow limitatio[...]

125 INDEX A Accesso ries 69 ................... Adjus tme nts 86-95 ................ Ag e Restrictio ns 11 ............... Air F ilter Serv ice 96 ............... All Whe el Dr ive 44 ............... Au tom atic Transmissio n 4 3 ......... Au xiliary B rake 87 ............... AW D 4 4 ........................ B Bat ter y 106-108 .................. [...]

126 INDEX M Main Sw itch 3 6 .................. MAINTENANCE AND LUBRICA TION 69- 112 ........ Ma inte nance R ec ord 74 ............ Ma king Tur ns 58 ................. Ma st er Cyli nder 39 ............... Max imu m T o win g C apacities 55 ..... N NOISE EMI SSION CONTROL SYSTEM 68 ................ O Odome ter 47 .................... Oil C hange 7[...]

Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DRUGS before or while operating this v ehicle. Carry Passengers. P art No. 9918213 Rev 02 PRINTED IN THE USA W ARNING Improper vehicle use can result in SEV[...]