Polaris Sportsman S manual

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

1 We’ve cr eat ed a web si t e j ust f or YOU! S T echnical ti ps S New product introductions S Event schedules S Parts and Se rvice M anual information S Exciting details about The W ay Out Ch ec k it out... www . polar i si ndust r ies. com/ owner[...]

2 Al l i nf orma t ion i n t his ma nua l i s bas e d on the la t e st produc t dat a and s pe c if ic a t ions a vai l abl e a t the t im e of pri nti ng. Pol ar i s Indus tr i es I nc . re s e rve s the r i ght to make pr oduct c ha nges a nd i mprove me nt s tha t ma y af fe ct illustratio n s o r ex p lan atio ns. No par t of thi s ma nua l s h[...]

3 WELC O ME Thank you f or purc hasing a Polar is vehicle , and welcome to our wor ld-wide fa mily of Polaris owne rs. W e proudly produc e an exc iting line of utility and r ec re ational pr oducts. Polar is Recreational V ehicles S Snowmobiles S All- terr ain ve hicles ( A T Vs) S W at ercraft S RANGER utility vehicle s S V i cto ry m ot o rcycl [...]

4 VE HICLE IDENTIFICATION NUMBERS The fra me vehic le i dentif ication number ( VIN)(1) a nd engine seria l number ( 2) are impor tant for model identif ication whe n registe ring your ve hicle, when obtaining insur ance , and when or dering replacem ent p arts . In t he event your vehi cle i s s tol en, t hes e numbers ar e esse ntial to the re co[...]

5 TABLE OF CONTENTS WELCO M E 3 ........................................ VEHICL E IDENT IF I CA T IO N NUM BERS 4 ............... T ABL E OF CONT ENT S 5 ............................. SAF ET Y 6 .......................................... CONTROLS 3 6 ...................................... FEA T URES 44 ....................................... OPE RA[...]

6 SA FETY Safety D ecals and Locations W arning d ecals h ave been placed on th e A TV for your prot ecti on. Read an d fo ll o w th e ins t ruct i on s o n each decal carefu l ly . If a decal bec omes illegible or c omes of f, contac t your P olar is deale r to purcha se a repl acem ent . R ep l acemen t safety decals are pro vi ded b y P ol ari s[...]

7 SA FETY Safety D ecals and Locations IMPR OPER T IRE PRESSUR E OR O VERLO ADIN G can cause loss of contr ol re sulting in SEVERE I NJURY O R DEA TH. TI RE PRESSUR E IN PSI ( KPa) : FRO NT 5 (34,5) REAR 5 (34,5) M AXIMUM WE IGHT CAP ACITY (Gr os s Vehicle W eight) INCLUDIN G MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 k g). Reduce speed and al low[...]

8 SA FETY Safety D ecals and Locations Mov ing parts haz ar d under belt- c lutc h guar d. T o prev ent s er ious injury, do not operate v ehic le w ith guard remov ed. Do not modif y engine or c lut c h. D oing s o c an c aus e part failur e, pos s ible imbalanc e, and exc es s ive engine RP M whic h c an r es ult in s er ious injury or deat h. NO[...]

9 SA FETY Safety D ecals and Locations ALL WHE EL DRIVE SWITCH Do not push s witc h to engage A WD if the rear wheels are spinning. This m ay c ause sev ere drive s haf t and c lutc h damage. See your Owner ’s Manual. 7079780 7079604 7170509 TRAILER MAX WEIGHT : 1500 LBS. (682 KG ) O N L EVEL G ROUN D 850 LBS. (386 KG ) UP TO 15 ° GRADE HITCH MA[...]

10 SA FETY Safe Riding G ear Always we ar c lothing suited to the t ype of riding. A TV riding requir es spec ial protec tive clothing for comf ort and to reduce the c hanc e of injury . 1. Helm et Y our he lmet is the most impor tant pie ce of prote ctive ge ar for sa fe r iding. A hel met can prev ent a sev ere head in j ury . S elect an ap pro v[...]

11 SA FETY Operator S afety Age Restr i ctions This vehi cle is an ADUL T VEHIC LE ONL Y . Operati on is p rohibi ted for anyone under 16 yea rs of age. Know Y our V ehi cle As the opera tor of t he vehic le, you are re sponsible for your per sonal saf ety , the safe ty of others, and the prote ction of our envir onment. Read a nd understa nd your [...]

12 SA FETY Operator S afety The f ollowing two pages ide ntify signal wor ds and symbols that appe ar in this manua l. Y our sa fety is involve d when the se words a nd symbols ar e used. Be come f amilia r with their mea nings bef ore re ading the manua l. The safet y alert sy mbol , on y our v ehicle or in this manual, aler ts you t o t he pot en[...]

13 SA FETY Operator S afety S Rea d this manual a nd all labe ls car efully , and follow the opera ting proce dures de scribe d. S Neve r opera te an A TV without proper instruc tion. T ake a training course . B eginners s hould recei ve traini ng from a certifi ed inst ructor . Co n tact an au t ho ri zed P o l aris A TV d eal er or cal l P ol ari[...]

14 SA FETY Operator S afety S Alway s hav e the A TV in s pect ed by an au th ori zed P o lari s d eal er if it ’ s been i nvolved i n an accident . S Ne ver oper ate on hills too steep for the A TV or for your abilitie s. Pra ctic e on smalle r hills bef ore a ttempting lar ger hills. S Alwa ys follow prope r proce dure s for climbing hills. Che[...]

15 SA FETY Operator S afety S W et bra kes may ha ve r educe d stopping ability . T est the br ake s afte r lea ving wa ter . If n ece ssar y , apply them lightly seve ra l times to allow frict i on t o dry o ut t h e pads . S Always che ck for obstac les or people behind the A TV befor e opera t- in g i n revers e. When i t ’ s s afe to pro ceed[...]

16 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A TV wit hout pr oper inst ruc t ion. WHA T CAN H APPEN The r isk of an accident is great ly inc reas ed if the oper at or does not know how t o oper ate t he A T V proper ly in diff erent sit uat ions and on diff erent t ypes of t er rain. HOW T O A VOID THE HAZ A RD Beginning and in[...]

17 SA FETY Operator S afety POTENTI AL HAZ A RD Carr ying a pass enger on an A T V . WHA T CAN H APPEN Carr ying a passenger great ly r educes t he operat or ’s ability t o balance and cont r ol t he A T V , which c ould caus e an acc ident and injury t o t he oper at or and/ or pas senger . HOW T O A VOID THE HAZ A RD Never c arr y a pas senger [...]

18 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing an A T V on paved sur f aces , inc luding sidewalk s, paths , park ing lots , and driv eways. WHA T CAN H APPEN A T V t ir es ar e designed f or off -r oad use. O per at ing on paved surf ac es may adv ers ely affect t he handling of t he A TV and could result in loss of contr ol, acc iden[...]

19 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A TV on public st r eet s, roads or highway s. WHA T CAN H APPEN The A T V could c ollide wit h anot her v ehicle. HOW T O A VOID THE HAZ A RD Never operat e t he A T V on any public st reet , r oad or highway , including dirt and gr avel r oads. I n m any s tat es it’s illegal t o [...]

20 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t his A T V wit hout wear ing an approv ed helmet , eye prot ect ion and pr ot ect ive c lot hing. WHA T CAN H APPEN Oper at ing an A T V without an appr oved helm et inc reas es t he ris k of a sev ere head injur y or deat h in t he ev ent of an accident . Oper at ing wit hout ey e prot e[...]

21 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A T V af t er consum ing alcohol or drugs . WHA T CAN H APPEN Consumpt ion of alc ohol and/or drugs could ser iously affec t operat or judgm ent . React ion t ime m ay be s lower and operat or balance and perc ept ion could be aff ect ed. Consuming alc ohol and/ or dr ugs bef ore or w[...]

22 SA FETY Operator S afety POTENTI AL HAZ A RD At t empt ing wheelies, jum ps and ot her s t unt s. WHA T CAN H APPEN At t empt ing s tunt s incr eases t he c hance of an acc ident , including an overt ur n. HOW T O A VOID THE HAZ A RD Never att em pt wheelies, jum ps, or ot her stunt s . Avoid exhibition driving. W ARNING[...]

23 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o inspec t the A T V bef ore oper at ing. Failur e t o proper ly maint ain t he A TV . WHA T CAN H APPEN Poor m aint enance inc reas es t he poss ibilit y of an acc ident or equipment dam age. HOW T O A VOID THE HAZ A RD Always inspec t y our A T V bef ore eac h use t o m ake sur e it ’s [...]

24 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex t ra caut ion when oper at ing the A T V on unf am iliar terrai n. WHA T CAN H APPEN Unfamiliar t errain ma y c ont ain hidden rocks, bumps, o r holes that could caus e loss of cont rol or over tur n. HOW T O A VOID THE HAZ A RD T ravel s lowly and us e ext ra c aut ion when operat[...]

25 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex tr a caut ion when oper at ing on exces siv ely rough, s lippery or loos e ter rain. WHA T CAN H APPEN Oper at ing on exc essiv ely r ough, slipper y or loos e t err ain could cause los s of t rac t ion or los s of cont r ol, which could r esult in an accident or ov ert urn. HOW T [...]

26 SA FETY Operator S afety POTENTI AL HAZ A RD T urning impr operly . WHA T CAN H APPEN Im proper t urns c ould caus e loss of c ont rol and lead t o a c ollision or overt ur n. HOW T O A VOID THE HAZ A RD Always f ollow proper pr ocedur es f or tur ning as descr ibed in the owner ’s manual. Prac t ice t ur ning at s low speeds befor e at t empt[...]

27 SA FETY Operator S afety POTENTI AL HAZ A RD Climbing hills im proper ly . WHA T CAN H APPEN Im proper hill clim bing could caus e loss of cont rol or over tur n. HOW T O A VOID THE HAZ A RD Always f ollow proper pr ocedur es f or climbing hills as desc ribed in the owner ’ s manual. Always chec k t he t err ain car ef ully bef ore as cending [...]

28 SA FETY Operator S afety POTENTI AL HAZ A RD T raveling downhill im proper ly . WHA T CAN H APPEN Im proper ly des cending a hill c ould cause los s of c ontr ol or overt ur n. HOW T O A VOID THE HAZ A RD Always f ollow proper pr ocedur es f or tr aveling down hills as descr ibed in t he owner ’s manual. NO T E: A spec ial t echnique is r equi[...]

29 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly c ross ing hills and t ur ning on hills. WHA T CAN H APPEN Im proper ly cr oss ing or turning as hills could caus e loss of c ontr ol or overt ur n. HOW T O A VOID THE HAZ A RD Never at t em pt to t ur n t he A T V ar ound on any hill unt il y ou’ve mast er ed t he t urning t echnique ([...]

30 SA FETY Operator S afety POTENTI AL HAZ A RD St alling, rolling bac kwards or impr operly dis mount ing while climbing a hill. WHA T CAN H APPEN The v ehicle c ould over t urn. HOW T O A VOID THE HAZ ARD Maint ain st eady speed when climbing a hill. If all f or ward speed is lost: Keep your weight uphill. Apply t he br akes . Lock t he par king [...]

31 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly operat ing over obs tac les. WHA T CAN H APPEN Oper at ing over obst acles could c ause loss of cont rol or over tur n. HOW T O A VOID THE HAZ A RD Bef ore oper at ing in a new area, chec k f or obst acles . Avoid operating ov er lar ge obst ac les suc h as r ock s and f allen tr ees when[...]

32 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A T V t hr ough deep or f ast - f lowing wat er . WHA T CAN H APPEN T ires may f loat , caus ing loss of t r act ion and loss of cont r ol, which could lead t o an ac cident or ov ert ur n. HOW T O A VOID THE HAZ A RD Avoid operating t he A T V t hrough deep or f ast -f lowing wat er [...]

33 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A TV wit h impr oper t ires , or wit h improper or unev en tire pre ssure. WHA T CAN H APPEN Use of impr oper t ires , or oper ation of t he A TV wit h impr oper or uneven t ire pr ess ure, could c ause los s of cont r ol or ac cident . HOW T O A VOID THE HAZ A RD Always use t he siz [...]

34 SA FETY Operator S afety POTENTI AL HAZ A RD Ov erloading t he A TV or c arr ying/ t owing car go impr operly . WHA T CAN H APPEN Ov erloading and t owing c an cause c hanges in v ehicle handling, which could lead t o los s of cont r ol or an ac cident . HOW T O A VOID THE HAZ A RD Never ex ceed t he s tat ed load c apacit y f or t his A T V . C[...]

35 SA FETY Operator S afety Oper at ing a damaged A T V can r esult in an ac cident wit h ser ious injury or deat h. A f ter any ov ert ur n or accident , hav e a qualified serv ice dealer inspec t t he ent ir e mac hine for poss ible damage, including (but not lim ited t o) brak es, t hrot t le and st eer ing systems. Saf e operat ion of t his r i[...]

36 CONTROLS Engine E lectr ical Switches Mod e/ Rev erse O v erri d e S wi tch (1) - This veh icle is e quipped with a re verse spee d limiter system. T o gain a dditional powe r while bac king, depr ess the override switc h. NOTE: The ove rride switc h also allows ac tivation of All Wh eel Dr ive (A WD) in re verse , if the A WD switc h is on. Thi[...]

37 CONTROLS Throttle Lever Eng i ne sp eed an d veh icl e moveme nt are c ontrolle d by pre ssing the t hrottle le ver (1) . The throttle le ver is spring lo aded . En gi ne s peed ret urn s to idle whe n the leve r is releas ed . This A TV is equippe d with Polar is Elec tronic Throttle Control (E TC), whic h is designed to re duce the risk of a f[...]

38 CONTROLS Light S witches The light switch is loc ated on the left ha ndleba r . It’ s used to turn the lights on and of f and to switc h the lights fro m HI to LO. NOTE: The lights won’ t work unle ss 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 an d rear b rak es are ap pl i ed[...]

39 CONTROLS Master Cylinder The bra ke fluid in the master cylinde r (1) , which is loca ted on the lef t handleba r , should be chec ked before each ri de. T he fl u id lev el ca n be see n through an indic ator window (2) on the top of the master cylinde r . This eye wil l appear d ark whe n the fluid le vel is full. Whe n fluid need s to be adde[...]

40 CONTROLS Park in g Bra ke Setting the P arking Br ake 1. Place the tr ansmission in first gea r (or in P ARK if equipped). 2. S qu eeze and rel ease t h e brak e leve r (1) two or thr ee time s, then sq ueeze an d h ol d . 3. Push the par k brake lock ( 2) forw ard to engage the bra ke. Rel eas e t he b rake l ev er . 4. T o relea se the parking[...]

41 CONTROLS Auxiliary Brake Y our Polar is A TV ha s an auxilia ry brak e (1) for a dded saf ety . It’ s locate d on the inside of the right floor board and is oper ated b y the right foot. The auxilia ry brake serv es as a b acku p t o t h e m ain bra ke system if the main system be comes inope ra tive. If the r ear w hee ls slide while using th[...]

42 CONTROLS Choke The choke a ssists i n starting a cold engine . R ef er to the engine star ting proc edure on page 53 for c orre ct choke and throttle settings during star ting. Fuel V alve The fu el val ve (1 ) i s l o cated on th e l eft s i de pane l. It has three positions: OFF: For vehicle stor age a nd when tran sporting. ON: F or normal op[...]

43 CONTROLS Autom atic T r ansm ission Gear Selector The tra nsmission gear se lector ( 1) is l oca ted on the right side of the vehic le. S hift pa tterns va ry , depe nding on your model. H: High Gear L: Low Gea r N: Neutral R: Rev er se P: P ar k (Sportsman 600/700 only) T o shift into HIGH or P AR K on the Sportsma n 600 or 700, you must first [...]

44 FEATURE S All W heel Dr ive (A W D ) System Po l aris 4-wh eel dri ve A TVs are equippe d with a unique , Polar is-ex clusive, A WD syste m, whic h is activa ted by a switc h (1) on the r ight handlebar . When the s w i t c hi so f f ,t h eA T Vi si n2w h e e l drive a t all times. Whe n the switch is on, the A TV is in A WD a nd the A WD indica[...]

45 FEATURE S In s tru men t Clu st er Y our A TV is e quipped with a n instrume nt cluster tha t sense s vehic le spee d from the right front whe el. The instrume nt cluster measur es distanc e in mile s as we ll as hours of opera tion. It also include s a re ver se spee d limiter f unction tha t limits the A TV’ s spee d to appr oximately 7- 9 m[...]

46 FEATURE S In s tru men t Clu st er Ri der Infor ma tion Ce nter The ride r infor mation ce nter is loca ted in the instr ument cluste r . All segme nts will light up for 2.5 sec onds at sta rt-up. NOTE: I f the instrume nt cluste r fails to illuminate , a ba ttery over -volta ge may ha ve oc cur red a nd the instrume nt cluste r may ha ve sh ut [...]

47 FEATURE S In s tru men t Clu st er Ri der Infor ma tion Ce nter The r ider informa tion ce nter h as 4 standa rd mode s: Mode 1 - Odometer Mode 2 - T ripmete r Mode 3 - T otal S ervic e Hours Mode 4 - T achome ter The re verse ove rride button on the left handle bar is also the mode button . NOTE: I f using t he mode button to progra m the rider[...]

48 FEATURE S In s tru men t Clu st er Ri der Infor ma tion Ce nter Dia gnos tic Mode The diagnostic mode is for inf ormationa l purposes only . P lease r eturn your A TV to your deale r for all major r epa irs. As long as the gauge is in the diagnostic mode, the wrenc h icon will re main lit. T o leave the dia gnostic mode, eithe r shift the machin[...]

49 FEATURE S In s tru men t Clu st er Ri der Infor ma tion Ce nter Dia gnos tic Mode S cr een 5: Progra mmable se rvice inte rva l The purpose of the progr amma ble servic e interv al is to provide the consume r and dea ler with a conve nient reminde r for routine mainte nanc e. When your vehic le leav es the fac tory , this fea ture is set at 50 h[...]

50 OPERATION Fuel Safety Gas oline is highly f lammable and ex plosiv e under c ert ain condit ions. S Always exer cis e ext rem e caut ion whenev er handling gasoline. S Always ref uel wit h t he engine st opped, and out doors or in a well vent ilat ed area. S Do not smok e or allow open flames or spar ks in or near t he area wher e ref ueling is [...]

51 OPERATION Br eak -In Per iod The br eak -in per iod for your ne w Polaris A TV is define d as the first te n hours of oper ation, or the time it takes to use the first two full tanks of gasoline . No single a ction on your pa rt is as importa nt as following the proc edure s for a prope r brea k-in. Care ful t re atment of a new engine will re s[...]

52 OPERATION Pr e - Ride Inspection Use the f ollowing che cklist to verif y that your vehic le is in proper wor king condition be fore each use. Item/Inspection Pr oced ure 1. T ires - Chec k condition and pr essure s. 2. Fuel tank a nd engine oil level - Fill both to their pr oper le vels. 3. All brake s - Chec k oper ation, adjustment a nd fluid[...]

53 OPERATION Star ting the Engi ne S tar ting a Col d Engi ne 1. Place the tr ansmission in neutral (or P AR K if equipped) and lock the par king 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 ria ble choke is fully on when the knob is pulled comple tely out. The choke is[...]

54 OPERATION Star ting the Engi ne S tar ting a W ar m Engi ne W ar m engines do not normally re quire the use of the choke . Using the choke c an cause the spa rk plug to become we t fouled. 1. Position the vehicle on a le vel surfa ce with the tra nsmission in neutr al (or P ARK if equipped) . 2. Lock the parking br ake, turn the fuel tan k valve[...]

55 OPERATION Hauling Cargo Y our A TV ha s been de signed to ca rry or tow a c erta in amount of load. Always r ead a nd under stand the load d istribution war ning labe ls on the veh icl e, an d nev er exceed t he wei gh t cap ac ities outline d in the sp ecifi cat i on s s ecti o n of t he own er ’ s m anu al an d on t h e safety d ecal s. Car [...]

56 OPERATION Hauling Cargo Hauling cargo im proper ly c an alt er v ehicle handling and m ay cause los s of c ontr ol or br ake ins t ability and res ult in serious injury or deat h. Alway s f ollow t hes e precaut ions when hauling car go: S REDUCE SPEED AND ALLO W G REA T ER DI ST ANCES F O R BRAKING WHEN HAULING C ARGO . S CARG O W EI G HT DIS T[...]

57 OPERATION Driving Safely Driving Pr ocedu res 1. Sit upright with both feet on the footre sts and both hands on the handle bars. 2. Start the engine a nd allow it to warm up, the n shift the tra nsmission into gea r . 3. Check your surr oundings and determine your path of tra vel. 4. Relea se the parking bra ke. 5. Slowly depre ss the throttle w[...]

58 OPERATION Driving Safely Making T urns Y our A TV is e quipped with a solid rea r a xle, which dr ives both re ar whe els equa lly at a ll times. This mea ns that the whee l on the outside of t he t u rn m u st t ravel a g reater d i st an ce th an t h e i ns id e wh eel when turning a nd the inside tir e must slip tra ction slightly . T o turn,[...]

59 OPERATION Driving Safely Dr iving o n Slippery S urfaces Whenev er rid i ng on s l i pp ery su rfaces su ch as wet t rai ls or l oo se grav el, or du rin g freezi ng weat her , fol l ow t hes e precaut i on s : 1. Slow down when e ntering slippe ry are as. 2. Mai n tai n a hi g h lev el o f alert nes s , read i ng t h e trai l an d avo id i ng q[...]

60 OPERATION Driving Safely T raveling Uphill Whe nev er tra veling uphill, follow these pr ecauti on s : 1. Alwa ys tra vel stra ight uphill. 2. A void steep hills ( 25 _ maximum) . 3. Kee p both fee t on the footre sts. 4. T ransf er your weight forw ard. 5. P roceed at a st eady r ate of s peed an d t hro ttle opening. 6. Rema in aler t and be p[...]

61 OPERATION Driving Safely Sidehilling Sidehilling ca n be a da ngerous type of driving a nd should be avoide d if at a ll possible. If you do e nter into a situation w here sidehilling is neces sary , fol l ow th ese p recau ti o ns : 1. Sl ow down. 2. Lea n into the hill, transf er ring your upper body weight tow ard the hill while keeping your [...]

62 OPERATION Driving Safely T raveling Downhill Whe neve r desce nding a hill, follow the se pr ecaut i o ns : 1. P roceed d i rectl y d ow nh ill. 2. T ra nsfer your we ight to the rea r of the vehic le. 3. Sl ow down. 4. Apply the brakes slightly t oa i di ns l o w i n g . Familia rize your self with oper ation of the auxilia ry brake in the eve [...]

63 OPERATION Driving Safely T urning A r ound on a Hi ll If the ve hicle sta lls while climbing a hill, never ba ck it down the hill! One mane uver tha t can be used when you must tur n around while climbing a hill is the K-turn: 1. Stop and lock the pa rking bra ke while kee ping body weight uphill. 2. Lea ve the tr ansmission in for war d and shu[...]

64 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV c an oper ate thr ough water with a maximum re comme nded depth e qual to the bottom of the footr ests (1). Follow th ese p roced ures when oper ating through water: 1. De termine w ate r depths a nd curre nt bef ore cr ossing. 2. Choose a crossing wher e both banks have gradua l i ncl[...]

65 OPERATION Driving Safely Dr iving Over Ob stacles Be al ert! Lo ok ah ead and l earn t o read th e terrai n yo u’re t ravel i ng o n. Be con s tan t l y alert fo r hazards s uch as l o gs , r ock s and l o w hang i ng bran ches . Sever e injury or deat h can r esult if your vehic le com es in cont ac t with a hidden obs t acle. Not all obs tac[...]

66 OPERATION Driving Safely Dr iving in Reverse F ol l ow th ese precau t io ns when o perat i ng i n rev erse: 1. Alwa ys avoid bac king downhill. 2. Back slowly . 3. Whe n in reve rse , apply the bra kes lightly for stopping. 4. A void t urning a t sh arp angl es i n rev erse. 5. Neve r open the throttle suddenly while ba cking. NOTE: Y our Polar[...]

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 unavoida ble, follow th es e precau ti o ns : 1. T urn the engine of f. 2. Place the tr ansmission in low range ( or park if equippe d). 3. Set t he parking bra ke. 4. Always block the rea r wheels on the downhill side as shown in the [...]

68 EMISSION C O NT RO L SYSTEMS Noise E m ission C ontrol S ystem T AM PER ING WITH NOIS E CONTR OL S YS TEM P R OHIBITED! U.S . F ede ral law prohibits the following acts or the causing the reof: (1) the remova l or re ndering inoper ative by a ny per son other than f or pu rpo ses o f mai n t enan ce, repai r , o r rep lacem en t of an y d evi ce[...]

69 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Care ful per iodic maintena nce will help keep your vehic le in t he saf est, most relia ble c ondition. Inspe ction, adjustment a nd lubrica tion of importa nt components ar e expla i ned i n the periodic maintena nce sche dule. Use the instrument cluste r ’ s progra mmable ser vic[...]

70 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Hours of ope ration a re ba sed on a 10 mph aver age. If servic e is due a t 20 hours, the e quivalent odome ter re ading w ould be 200 miles. P erform al l serv i ces at whi chever readi ng i s reached fi rst . Item Hours/ Mile s Fr equency Remarks Brake S ystem Pre- Ride Pre- Ride I[...]

71 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Item Hours/ Mile s Fr equency Remarks " Air box sediment tube Pr e-Ride Pr e-Ri de Drai n deposit s whenever visi ble Headlam p Pre- Ride Pr e-Ri de Check oper ati on daily; ap- ply P olar is di elect ri c gr ease to connect or when r eplaced T a il la mp /b ra k e lam p Pre- Rid[...]

72 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Item Hours/ Mile s Fr equency Remarks Carbur etor fl oat bowl 50 hr s. 6 mont hs Drai n bowl peri odical ly and pri or t o stor age J Throt tle Cabl e/ ETC Swit ch 50 hr s. 6 mont hs Inspect ; adjust; l ubr icat e; r eplace if necessar y L Choke (enr icher) cable 50 hr s. 6 months I n[...]

73 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Item Hours/ Mile s Fr equency Remarks " Rear axle 50 hr s. 6 mont hs In spect beari ngs; lube J L Igni t ion T im ing 100 hr s. 12 mont hs Inspect ; adjust as needed J L Fuel system 100 hours 12 mont hs Check for l eaks at t ank cap, li nes, f uel valve, f il ter , pump and car b[...]

74 MAINTENANCE AND LUBRICATION Per i odic Maintenance Recor d Use t he fo l lo wi ng chart to record peri od i c mai n ten ance. Maintenance In t erval Perfo rmed Se rv icing Date Se rv icing Dealer or Pe rs on Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.[...]

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

76 MAINTENANCE AND LUBRICATION Lubr ication G uide NOTE: Hour s in t he fr equenc y column a re ba sed on 10 mph aver age. If se rvice is due at 20 hours, the equivale nt odometer re ading would be 200 mile s. Perf orm a ll servic es a t whic heve r re ading is r eached firs t . Lubr icati on Guide Ke y " More often unde r seve re u se, such a[...]

77 MAINTENANCE AND LUBRICATION Lubr ication G uide (Fig. 1 ) (Fig. 4 ) (Fig. 2 ) (Fig. 3 ) (Fig. 5 ) (Fig. 1 ) (Fig. 2 ) (Fig. 6 )[...]

78 MAINTENANCE AND LUBRICATION Pr em i um 4 S yntheti c Lubr icant Polaris Pre mium 4 All S ea son synthetic e ngine oil has be en spe cially for mulated f or use in P olar is 4-c ycle engine s. It’ s a fully synthetic, high per for mance , multi-viscosity oil de signed to pr ovide the ultima te in lu bri cat i on p erform ance an d pro t ecti o [...]

79 MAINTENANCE AND LUBRICATION Oil Check The oil dipstick and fill tube (1) ar e locate d on the left side of the vehic le. 1. Position the A TV on a level surf ace. 2. Start the engine and let it idle for 20-30 se conds. 3. Stop the engine. Remove the dipstick a nd wipe it dry w ith a clean cl o t h. NOTE: If your dipstick is e quipped with a leve[...]

80 MAINTENANCE AND LUBRICATION Oil and Filter Change The r ecomme nded oil c hange inte rva l is 100 hours, 1000 miles, or eve ry six months, whic heve r come s fir st. Suggested br ea k-in oil cha nge is a t 20 hour s, 200 miles, or one month, w hiche ver comes first. Sever e use opera tion require s more fre quent servic e. S ever e use include s[...]

81 MAINTENANCE AND LUBRICATION Oil Change (400/500) 7. Plac e shop towe ls bene ath the oil filte r . Using an oil f ilter w renc h, turn the filte r (1) counte rcloc kwise and re move. 8. Lubric ate the gaske t on the new filte r with a film of new engine oil. Check to ma ke sure the ga sket is in good condition. Also make sur e the gaske t from t[...]

82 MAINTENANCE AND LUBRICATION Oil Change (600/700) 1. P lace t h e veh i cle o n a lev el su rface. 2. Run the engine for two to thre e minutes until wa rm. Stop the engine . 3. Clean the ar ea a round the drain plug. 4. Place a dr ain pan bene ath engine c rankc ase and re move the dra in plug. 5. Allow the oil to dra in comple tely . 6. Replac e[...]

83 MAINTENANCE AND LUBRICATION T r ansm ission Oil (400/500) The tra nsmission oil level should b e chec ked e very six months or 1000 miles ( 1600 km), whiche ver c omes fir st. T ra nsmission oil should be cha nged annua lly . W e re commend the use of Polar is P re mium Synthetic Gea rca se Lubrica nt. S ee page 121 for the pa rt numbers of Pola[...]

84 MAINTENANCE AND LUBRICATION Front Gear case Oil (400/500) The f ront gear case lubrica nt level should be c hec ked eve ry six months or 1000 miles (1600 km), whiche ver come s first. F ront gea rca se oil should be change d annually . Use Polaris Premium Synthetic Gea rca se Lube (or GL5 80-90 weight gear lube ). S ee page 121 for the par t num[...]

85 MAINTENANCE AND LUBRICATION T r ansm ission Oil (600/700) The tra nsmission oil level should b e chec ked e very six months or 1000 miles ( 1600 km), whiche ver c omes fir st. T ra nsmission oil should be cha nged annua lly . W e re commend the use of Polar is P re mium Synthetic Gea rca se Lubrica nt. S ee page 121 for the pa rt numbers of Pola[...]

86 MAINTENANCE AND LUBRICATION Front Gear case Oil (600/700) The f ront gear case lubrica nt level should be c hec ked eve ry six months or 1000 miles (1600 km), whiche ver come s first. F ront gea rca se oil should be change d annually . W e rec ommend the use of Polar is Premium Hub Drive Fluid. See pa ge 121 for the part numbers of P olaris prod[...]

87 MAINTENANCE AND LUBRICATION Rear Gearcase Oil (600/700) The r ear gea rca se lubric ant leve l should be che cked e very six months or 1000 miles (1600 km), whiche ver come s first. Rear ge ar case oil should be change d annually . Use Polar is P re mium S ynthetic Ge arc ase Lube (or GL5 80-90 weight gea r lube). NOTE: See page 121 for the par [...]

88 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Coolant Level The r ec overy bottle (1) is loc ated on the left s id e of th e m achi ne. T o acces s th e re cover y bottle, remove the lef t side pane l as outline d on page 93. The fluid leve l must be maintained betw een the minimum and ma ximum mar ks on the bottle (when the fluid is cool[...]

89 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Radiator Coolant Level NOTE: This pr ocedur e is re quired only if the c ooling system has be en dra ined for mainte nanc e and/or re pair . Howe ver , if the rec overy bottle has run dry , the leve l i n the radiator should be inspe cted a nd coolant added i f neces sary . 1. Using the tool p[...]

90 MAINTENANCE AND LUBRICATION Fr ont Br ake The front bra kes are hydr aulic disc bra kes. They’r e activa ted by moving the brake le ver toward the handle bar . These br akes ar e self -adjusting. The fo l lo wi ng checks are recom m end ed t o keep t h e brak e sy st em in good oper ating condition. Chec k more of ten if br akes a re use d hea[...]

91 MAINTENANCE AND LUBRICATION Rear Br ake The re ar bra ke is a hydraulic disc bra ke and is act i vat ed b y th e sam e l ev er t hat act iv at es the front bra ke system. The rea r brake system is self -a djusting and re quires no mainte nanc e other than per iodic chec ks of th e pad s fo r wear . Pads should be c hanged whe n worn to 3/64 ″ [...]

92 MAINTENANCE AND LUBRICATION T oe A li gnm ent Use the following proce dure to chec k the t oe alignme nt of t he vehic le. The re comme nded toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set t he handle bars in a stra ight-ahe ad position. NOTE: The st eerin g fro g can be us ed as an i nd i cato r of whether the ha ndlebar s are stra ight. Th[...]

93 MAINTENANCE AND LUBRICATION Si de Pa nel Rem oval NOTE: Side panel r emoval ma y be dif ficult until the locking ta bs and receiv ers hav e been sn app ed and un s napp ed a few times. 1. Remove the sea t. 2. Grasp the rea r of the side pan el n ear t he rear cab . W i t h a quic k and fir m motion, pull th e panel fo rward and ou tward to disen[...]

94 MAINTENANCE AND LUBRICATION T ir e T r ead De pth Alway s repl ace ti res when t read depth is wor n to 1/8 ″ (.3 cm) or less. See illustr ation. Wheel Rem oval 1. Stop the engine, plac e the transmission in gea r (or in P ARK if equipped) and lock the par king brake . 2. Loosen the whe el nuts slightly . 3. Eleva te the side of the vehicle by[...]

95 MAINTENANCE AND LUBRICATION Wheel Installation 1. Place the tr ansmission in gear (or in P AR K if equipped) and loc k the parking br ake. 2. P lace t h e wh eel o n t h e wheel hu b wi t h t he v al ve s tem towar d the outside and rota tion ar rows on the tire pointing toward f orward rota tion. 3. Install the wheel nuts a nd finger tighten. 4[...]

96 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service 1. Rem o ve t h e seat , rel eas e t he air box cove r clips, and re move the air box cover . 2. Loosen the cla mp and re move the filte r . 3. Remove the fa bric type pre -filte r (1) f rom the main filte r (2). W ash the pre -filte r in s o apy wat er , then ri n se and let d ry . [...]

97 MAINTENANCE AND LUBRICATION Lights Whe n ser vicing a ha logen lamp, don’ t touch the la mp with bare finger s. Oil fr om your skin le ave s a re sidue, ca using a hot spot tha t will shorten the life o f the lamp. Headlight L amp Replacem ent 1. Remove the two screws on the lower front corne rs of t he headlight pod. 2. Usi ng a sm al l fl at[...]

98 MAINTENANCE AND LUBRICATION Lights High Be am Ad just ment The h eadlight be am ca n be a djusted to any position d esire d by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a leve l surfa ce with the hea dlight appr oximate ly 25 ft. (7.6 m) from a wall. 2. Mea sure the distanc e fro m t he [...]

99 MAINTENANCE AND LUBRICATION Lights Headlight Hou sing Replacement 1. Remove the two screws on the lower front corne rs of t he headlight pod. 2. Usi ng a sm al l fl at -bl ade screwd ri ver , p us h in o n t he lo ck t ab through the two small openings at the f ront of the hea dlight pod. 3. Lift the pod slightly while depre ssing the tabs. 4. R[...]

100 MAINTENANCE AND LUBRICATION Lights Lower Headlam p Removal / Installation 1. T urn the bac k of the he adlight har ness (1) in a cloc kwise direc tion. 2. Pull the ha rness assembly out f rom the headlight asse mbly . 3. Remove the h ead lamp and re plac e with a new he adla mp. 4. Ins tal l t he new head l amp an d h arnes s ass em bl y into t[...]

101 MAINTENANCE AND LUBRICATION Spar k P l ugs S Use BKR5E spark plugs f or the Sportsman 400 a nd 500. S Use RC7YC spark plugs for the Sportsman 600 a nd 700. S Proper ele ctrode ga p i s . 035 ″ (.90 mm). S Spark plug torque is 18 ft. lbs. (24 Nm). Spar k plug condition is indica tive of e ngine oper ation. The spa rk plug firing e nd condition[...]

102 MAINTENANCE AND LUBRICATION V eh ic le Imme rs io n If it’ s impossible to take your A TV to a deale r befo re star ting it, follow the steps outlined below . 1. Move the A TV to dry land or at the very lea st, to wate r below the footr ests. 2. Check the a ir box for any water a nd dry it if wate r is prese nt. Filter repl acem ent i s req u[...]

103 MAINTENANCE AND LUBRICATION Spar k A r r estor Use t he fo ll o win g p roced ure t o peri od ical l y p urge accum ul at ed carb on fr om the exha ust pipe/muf fler . 1. Remove the ar restor c lean- out plug (1) fr om the bottom of t he muf fler . 2. Place the tr ansmission in neutral (or P AR K, if equipped) and star t the engine . 3. Pur ge [...]

104 MAINTENANCE AND LUBRICATION PV T S ystem The basic ope ration of the Polaris PVT system is dependent on engine sp eed an d v ehi cl e to rqu e requ irem en ts . As engi n e sp eed i n creases , th e for ce exe rted on the movable drive shea ve by t he flyweights also incr ease s. This, in tur n, incre ase s the amount of pinch a p p l i e dt ot[...]

105 MAINTENANCE AND LUBRICATION PV T S ystem PVT Dryi n g There m ay be so me i ns tan ces when wat er i s accid ent l y i ng est ed i nt o the PVT system. Use the following instruc tions to dry it out before oper ating: 1. Remove the dr ain plug and allow the wa ter to dra in. Repla ce the dra in plug. 2. Start the engine and shift the tra nsmissi[...]

106 MAINTENANCE AND LUBRICATION Batter y Y our A TV ma y have eithe r a se aled ba tter y , which re quire s little mainte nanc e, or a conventiona l batter y . Keep the conve ntional batte ry term i nal s and co nn ecti o ns free of corros i on . If clean i ng i s neces sary , re move the cor rosion with a stif f wire b rush. W ash with a solution[...]

107 MAINTENANCE AND LUBRICATION Batter y Batt ery Remo val 1. Disconne ct the hold- down strap holding the batte ry in position, and re move batter y cover . 2. On conventiona l batter ies, remove the batte ry vent tube. 3. Dis con nect t he b lack (neg ati v e) bat t ery cab le fi rs t . 4. Disconne ct the red (positive ) batte ry cable ne xt. 5. [...]

108 MAINTENANCE AND LUBRICATION Batter y Batter y S torage When th e veh i cl e is p laced i n s t orag e for th ree m on t hs or m o re, th e batte ry should be r emoved, store d out of the sun in a c ool, dry plac e and te sted monthly . B ef ore r eusing, take the batte ry to your de ale r for testing a nd rec har ging. Power plug lea ds may nee[...]

109 MAINTENANCE AND LUBRICATION Batter y Batter y Char ging (Sealed B attery) For a re fre sh char ge, follow all instruc tions ca ref ully . 1. Chec k the batter y voltage with a voltme ter or multime ter . A fully cha r ged ba tter y will register 12.8 V or higher . 2. If the volta ge is less than 12. 8 volts, re char ge the batte ry . NOTE: When[...]

11 0 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry power outle ts provide 12V powe r for oper ating acces so ries such a s hand held spot lights. Acc essory outle ts are ava ilable f or all mo del s . P ol ari s als o h as a wi d e rang e of ad di t io nal acces so ries ava ilable f or your A TV . See your Polaris dea ler . Cleaning a nd Stor[...]

111 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s Clean t he Exterio r Make nec essar y repa irs a nd then cle an the A TV thoroughly with mild soap a nd war m wate r to re move all dirt a nd grime. Don’ t use harsh dete r gents or high pressur e washer s. S ome dete r gents dete riorate r ubber parts. Use dish soap type cle[...]

11 2 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s Fog the E ngine 1 . Remove the spa rk plug an d add 2-3 table spoons of Premium 4 S yn th et i c 0W4 0 en gi n e oi l . T o acces s th e pl ug ho le, us e a s ect io n of clear 1 / 4” h os e an d a s m all pl as t ic s q ueeze b o ttle fille d with the pre -mea sured amount [...]

11 3 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s Batte r y Mai nte na nc e (Conve nti ona l) Remove the ba tter y and a dd distilled wa ter to the prope r lev el. Do not use tap w ater , wh i ch may co nt ai n m in eral s t hat red uce bat t ery l if e. Appl y di el ectri c g rease t o t h e term i nal b ol t s an d t erm i [...]

11 4 ADJUSTME NTS Cam ber and Caster The ca mber and ca ster a re non-a djustable . Rear S pr ing The re ar shock absor ber spring is adjuste d by rota ting the ad juster ( 1) eit h er cl ock wi se o r counte rcloc kwise to i ncr ease or decreas e sp ri ng t ens i on . NOTE: A cce ssory springs ar e ava ilable through your Polar is deal er . Handle[...]

11 5 ADJUSTME NTS Car bur etor / Idl e RP M If the e ngine idle speed is not satisfa ctory , and all other conditions ar e favora ble, the carbur etor can b e adj us t ed. 1. W arm up the engine by running the vehic le for a pproximate ly five minutes. 2. Plac e the tr ansmission in ge ar w ith the par king brake a pplied. 3. Adjust the ca rbure to[...]

11 6 ADJUSTME NTS Thr ottle Cabl e Fr eeplay Thr ottle ca ble fre epla y is adjusted at the handle bar . 1. Slide the boots (1) of f the inline cab le adjuster sle eve ( 2). Loosen the adjuste r locknut (3). 2. T urn the adjuste r until 1/16 ″ to 1/8 ″ freepl ay is achi ev ed at t he th um b l ev er . NOTE: Wh ile adjusting fre epla y , be sure[...]

11 7 TROUB LES HOOTIN G Dr ive Belt an d Cover Pr ob lems Po ssi b l e Cause Solution Dr ivi ng t he A TV onto a p ick u p o r tall trailer in hi gh ra nge . Shi ft tr a nsm is s ion t o low ra nge duri ng loa ding of the A TV t o pre ve nt bel t burni ng. St ar t ing out going up a steep in clin e. Whe n s ta rt ing out on an i ncl ine , us e l ow[...]

11 8 TROUB LES HOOTIN G Contac t your P olar is deale r for ser vice if you’ re unable to identif y solutions using the follow ing char ts. Engine Doesn’t T urn Over Po ssi bl e Cause Sol uti o n Trip p ed circu it b reak er Reset th e b reak er Lo w battery v o ltage Re cha r ge ba tt er y to 12. 5 VDC Loos e bat t er y c onnec ti ons Ch eck a[...]

11 9 TROUB LES HOOTIN G Engine Backfir es Po ssi bl e Cause Sol uti o n W ea k spa rk f rom s pa rk pl ugs In sp ect, clean and /o r repl ace sp ark p lu g s In co rrect spark p lu g g ap o r h eat rang e Se t gap to spe c s or re pl ac e pl ugs Ol d or non- r ec omme nded f ue l Re pla c e wit h ne w f uel In co rrectly in stalled sp ark p lu g w [...]

120 TROUB LES HOOTIN G E ngine St ops or Loses P ower Po ssi bl e Cause Sol uti o n Out of fuel Tu rn fu el valv e to reserve, refuel Ki nked or plugge d fue l ve nt li ne In sp ect an d rep lace W ater p resen t in fu el Re pla c e wit h ne w f uel Ove rus e of choke In sp ect, clean and /o r repl ace sp ark p lu g s Foul ed or de fe c ti ve spa r[...]

121 POLARIS PRODUCTS Part No. Descri pti on Engine Lubr icant 2870791 Fogging O il (12 oz. Aer osol ) 2871281 Engine O il (qt . ) Pr emium 4 Synthet ic 0W -40 ( 4-Cycl e) 2871844 Engine O il (gal .) Pr emi um 4 Synthet ic 0W -40 ( 4-Cycl e) Gear case / T ransmi ssi on Lubri cants 2871477 Prem ium Synt hetic G earcase Lubr icant ( 1 gal. ) 2871478 P[...]

122 SPECIFIC AT IO NS SPORT SM AN 40 0 Gro ss V eh icle W eigh t 1200 l bs. /544 kg T owi ng Capa c it y 1225 l bs. /556 kg Hi tc h T ongue Capa ci ty 120 l bs. /54 kg ( Rea r ra ck w ei ght a nd tongue weig h t n o t to exceed 1 8 0 lb s./8 1 .6 k g ) F ro n t R ack C ap acity 90 l bs. /40. 8 kg Rear R ack C ap acity 180 l bs. /81. 6 kg Ov erall L[...]

123 SPECIFIC AT IO NS SPORT SM AN 40 0 Shi ft T ype Side Leve r (H igh, Low , Neut ra l, Re ve rs e ) Gear R ed u ctio n - L o w 8.27/ 1 Ge ar Re duct ion - Reve rs e 5. 17/ 1 Gear R ed u ctio n - F o rw ard 3.34/ 1 Driv e R atio - F ro n t 2:1 Driv e R atio - F in al 3.16: 1 Tire, Fro n t 2 5x8- 1 2( 5p s i ) Tire, Rear 2 5x1 1- 1 2( 5p s i ) Fron[...]

124 SPECIFIC AT ION S SPORT SM AN 50 0 Gro ss V eh icle W eig h t 1200 lbs ./ 544 kg Hitch T o w in g R atin g 1 225 l bs ./ 556 k g Un b raked Trailer T o w in g C ap acity * 1786 lbs ./ 810 kg Hi tc h T ongue Capa c it y 120 lbs ./ 54 kg (Re a r r a ck w ei ght a nd tongue weig h t no t to ex ceed 1 8 0 lb s./8 1 .6 k g ) Fr o n t R ack C ap acit[...]

125 SPECIFIC AT IO NS SPORT SM AN 50 0 Driv in g S y stem T y p e EBS Shi ft T ype Side Leve r (H igh, Low , Neut ra l, Re ve rs e ) Gear R ed u ctio n - L o w 8.27/ 1 Ge ar Re duct ion - Reve rs e 5. 17/ 1 Gear R ed u ctio n - F o rw ard 3.34/ 1 Driv e R atio - F ro n t 2:1 Driv e R atio - F in al 3.16: 1 Tire, Fro n t 2 5x8- 1 2( 5p s i ) Tire, R[...]

126 SPECIFIC AT IO NS SPORT SM AN 60 0 Gro ss V eh icle W eigh t 1240 l bs. /563 kg F u el Cap acity 4. 75 ga l. /18 l T owi ng Capa c it y 1500 l bs. /681 kg Hi tc h T ongue Capa ci ty 1 5 0 lb s./6 8 .1 k g (R ear rack capacity an d t ongue we ight not t o e x ceed 2 0 0 lb s./9 0 . 7 k g ) F ro n t R ack C ap acity 100 l bs. /45. 4 kg Rear R ack[...]

127 SPECIFIC AT IO NS SPORT SM AN 60 0 Shi ft T ype Side Le ver (Hig h , Lo w , N eu tral, R ev erse, Park ) Gear R ed u ctio n - L o w 7.5/ 1 Ge ar Re duct ion - Reve rs e 5. 1 1/1 Ge ar Re duct ion - High 3.09/ 1 Driv e R atio - F ro n t: 3.82/ 1 Driv e R atio - F in al 3.10/ 1 Tire Size - F ro n t 2 5x8- 1 2 Tire S ize - R ear 2 5x1 1- 1 2 Front[...]

128 SPECIFIC AT IO NS SPORT SM AN 70 0 Gro ss V eh icle W eigh t 1240 l bs. /563 kg F u el Cap acity 4. 75 ga l. /18 l T o w in g R atin g 1500 lbs ./ 681 kg Un brak ed Trailer T o w in g C ap acity * 1914 l bs. /868 kg F ro n t R ack C ap acity 100 l bs. /45. 4 kg Rear R ack C ap acity 200 l bs. /90. 7 kg Hi tc h T ongue Capa ci ty 1 5 0 lb s./6 8[...]

129 SPECIFIC AT IO NS SPORT SM AN 70 0 Shi ft T ype Side Le ver (Hig h , Lo w , N eu tral, R ev erse, Park ) Gear R ed u ctio n - L o w 7.5/ 1 Ge ar Re duct ion - Reve rs e 5. 1 1/1 Ge ar Re duct ion - High 2.89/ 1 Driv e R atio - F ro n t: 3.82/ 1 Driv e R atio - F in al 3.10/ 1 Tire Size - F ro n t 2 5x8- 1 2 Tire S ize - R ear 2 5x1 1- 1 2 Front[...]

130 WARRANTY LIM IT ED W ARRANTY Polaris Sa les Inc ., 2100 Highway 55, Medina, MN 55340, gives a S IX MONTH LIMITED W ARRANTY on all components of the Polaris All T errai n V ehi cl e (A T V) agai ns t defect s i n mat eri al or wo rkm ans hi p . Polar is also gives a one yea r limited wa rra nty on the final drive ch ain for fa ilure due to def e[...]

131 WARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIM IT A T IONS OF W ARRANT IES AND REM EDIES The Polaris limited war ranty e xcludes a ny fa ilures tha t are not cau sed by a de fec t in mater ial or workma nship. This warr anty does not cove r accid ent al d amag e, n orm al wear and t ear , ab us e or i m p rop er han dl i ng . This warr anty a[...]

132 WARRANTY ALL IMPLIED W ARR ANTIES (INC LUDING B UT NOT LIMITED T O THE IMP LIED W AR R ANTIES OF MER C HANT AB ILITY AND FITNES S FOR A P AR TIC ULAR P UR P OSE) AR E LIMITED IN DURA TION TO THE ABOVE SIX M ONTH W AR RANTY P ER IOD. POLAR IS FUR THER DIS CLAIMS ALL EXPR ES S W ARR ANTIES NOT ST A TED IN THIS W ARR ANTY . S om e stat es do not a[...]

133 WARRANTY Exported V ehicles EX CEPT W HER E SPECIFI CAL L Y REQ UI RED BY LA W , THE RE IS NO W ARR ANTY OR S ER VICE B ULLETIN C OVERAGE ON THIS VEHIC LE IF IT IS S OLD OUTSIDE THE C OUNTR Y OF THE SELLING DEALER ’S AUTHORIZED LOC A TION. Thi s p ol i cy d oes n ot ap pl y t o veh i cl es th at h ave recei ved au t ho ri zati o n for export [...]

134 WARRANTY Exported V ehicles How to G e t Se rv i ce If Purchased From A Private Party: If you purch ase a Polaris produc t from a private c itizen outside of the countr y in which the ve hicle w as origina lly purcha sed, all war ra nty cove rage will be denie d. Notic e If your vehic le is registe red outside of the country wher e it was pur- [...]

135 INDEX A Accessori es 110 .................... ADJUSTM ENTS 11 4 - 11 6 ........... Age R estrictio ns 1 1 ................. Air F ilter Service 96 ................ All W h ee l Dr i v e 4 4 ................. Autom atic T ransmission 43 ........... Auxiliary Brake 91 ................. AW D 4 4 .......................... B B attery 107-109 ......[...]

136 INDEX M Main S witch 3 6 .................... MAINTENANCE AND LUBRICA TI ON 6 9 - 11 3 .... Mai ntenance Record 74 .............. Maki ng T urns 58 ................... Master C ylinder 39 ................. N Noi se Em ission Cont rol System 68 ..... O O dometer 47 ...................... O il Change 80 ..................... O il Change (400/500)[...]

P art No. 9918540 Rev 04 PRINTED IN THE USA W ARNING Impr oper vehicle use can r esult in SEVERE INJUR Y or DEA TH. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND W ARNINGS. AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WITH DRUGS OR ALCOHOL Operate without pr oper training [...]