Univex Sportsman 700 EFI manual

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P art No. 9919426 Rev 02 PRINTED IN THE USA W ARNING Improper 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 proper training or[...]

A car d containing impor tant A T V safet y infor mation s hould be attac hed to t he owner ’s manual on the nex t page. If you cannot locat e this car d, or if it has been r emoved, pleas e call 1-800-342-3764 f or assis tance. The engine exhaust from this product contains chemical s known to cause cancer , birth defects or other reproductive ha[...]

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2 Copyri ght 2004 Pola ris Sal es Inc . Al l inf orma ti on conta ine d wit hin thi s publi cat ion is bas ed on the l ate st produc t infor mat ion at t he time of publ ica tion. Due to cons ta nt imp rov ements in the desig n and q uality o f pr oducti on com ponent s, som e mi nor discrep ancies may resu lt betw een the actual veh icle an d the [...]

3 WELC OME Thank you for purchasing a Polar is vehicle , and welc ome to our world-w ide family of Polar is owners. W e proudly produce an exc iting line of utility a nd recr ea tional produc ts. Polaris R ecreational V ehicles S Snowmobiles S All-te rrain ve hicles ( A TVs) S W atercraft S RANGER utility vehicle s S V icto ry mot orcycl es W e bel[...]

4 VEHICLE IDE NTIFICATION NUMBERS Recor d your A TV’ s identific ation numbe rs and ke y number in the spaces prov ided. R emov e the s pare key and sto re it i n a safe p lace. Y our key can be duplicated only by mating a P ola ris key bla nk with one of your existing ke ys, so if both keys a re lost, the ignition sw itch mus t be rep laced. V e[...]

5 TABLE OF CONTENTS WELCOM E 3 ........................................ VEHICLE I DENTIF ICA TIO N NUMBERS 4 ............... SAFET Y 6 .......................................... FEA TURES AND CONT ROLS 32 ...................... OPER A TION 46 ..................................... EMISSI ON CONT ROL SYSTEM S 63 ................... MAINTENANCE AND LU[...]

6 SAFE TY Safety D ecals and Locations W arning decal s have been placed on the A TV for your protecti on. Read and fo llo w the i nst ructio ns of the d ecals on the A TV carefu lly . If an y of the decals depi cted in this m anual differ from the decals o n your A TV , al ways read and fo llo w the i nstru ctio ns of t he decal s on the A T V . I[...]

7 SAFE TY Safety D ecals and Locations A TTE NTION S Operat ion of this v ehicle w ithout the air filter element will s ever ely damage the engine. S Clean pre- filter element often, more frequent c leaning required in dus ty conditi ons. Do not operate v ehicle w ithout pre-filt er . 7172921 IMPRO PER TIRE PRESSUR E OR O VERLO ADING can cause loss[...]

8 SAFE TY Safety D ecals and Locations S DO NOT TOW FROM RACK OR BUMPE R. V ehic le damage or tipov er may r esult c ausing s ever e injury or death. T ow only f rom tow hooks or hit ch. S Max R ack Loads : Front 100 lbs . (45 k g) Rear 200 lbs . (91 k g) 7172749 S Moving parts haz ard under belt-c lutch guard. T o prev ent serious injury, do not o[...]

9 SAFE TY Safety D ecals and Locations ALL WHEEL DRIVE SWITCH Do not push s w itc h to engage AW D if t he rear wheels are s pinning. This may cause severe drive shaf t and c lutch damage. See your Owner ’s Manual. 7079780 7170509 TRAILER MAX WEIGHT : 1500 LBS. ( 682 KG) O N L EVEL GRO UND 850 LBS. ( 386 KG) U P TO 15 ° GRADE HITCH MAX. VERTICAL[...]

10 SAFE TY Safe R iding Gear Always wea r clothing suite d to the t ype of riding. A TV riding require s specia l protective c lothing for c omfort and to reduc e the cha nce of injury . 1. Helmet Y our helmet is the most important pie ce of protec tive gea r for safe riding. A helm et can p revent a severe head inj ury . Sel ect an approv ed helm [...]

11 SAFE TY Operator S afety W ARNING Failur e to follow t he warnings cont ained in this m anual can result in severe injur y or deat h. A Polar is A TV is not a toy and can be hazardous to operat e. T his vehicle handles different ly than ot her vehicles, such as motorcycles and cars. A collision o r rollover can occur quickly , even during r outi[...]

12 SAFE TY Operator S afety The following signa l words and symbols a ppea r throughout this manual a nd on your vehic le. Y our safe ty is involved whe n these wor ds and symbols are use d. Become f amilia r with their mea nings befor e rea ding the manua l. The safety aler t sym bol , on your v ehicle or in this manual, aler ts you to t he potent[...]

13 SAFE TY Operator S afety W ARNING Serious injury or deat h can result if y ou do not follow t hese instr uctions and procedures , which are out lined in furt her detail within your owner ’s manual. S Read this ma nual and all labe ls car efully , and follow the ope rating proce dures de scribe d. S Never ope rate a n A TV without proper instru[...]

14 SAFE TY Operator S afety S Always have th e A TV i nspect ed by an aut horized P olari s dealer i f it’ s been invol ved in an accident. S Neve r oper ate on hills too steep for the A TV or for your a bilities. Pra ctic e on smalle r hills befor e atte mpting la r ger hills. S Always fo llow proper pr ocedure s for climbing hills. Check the te[...]

15 SAFE TY Operator S afety S W et bra kes may have r educe d stopping ability . T est the br ake s afte r lea ving wate r . If nec essa ry , apply the m lightly seve ral time s to allow frict ion to d ry out t he pads. S Always chec k for obstacle s or people behind the A TV be fore ope rat- ing i n reverse. Wh en it’ s safe to p roceed in rever[...]

16 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Oper ating this A TV wit hout proper ins truct ion. WHA T CAN HAPPEN The r isk of an ac cident is gr eatly incr eased if t he operator does not know how to operat e the A TV properly in diff erent s ituations and on different ty pes of t errain. HOW TO A VOID THE HAZA RD Beginning and inexper i[...]

17 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Carry ing a passenger on an A TV . WHA T CAN HAPPEN Carry ing a passenger great ly reduces the operat or ’s ability to balance and contr ol the A TV , which could caus e an accident and injury t o the operat or and/or pas senger . HOW TO A VOID THE HAZA RD Never c arry a pass enger . The pur [...]

18 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Oper ating this A TV on public str eets, roads or highways. WHA T CAN HAPPEN The A T V could collide wit h another v ehicle. HOW TO A VOID THE HAZA RD Never oper ate the A T V on any public st reet, road or highway , including dirt and gravel r oads. I n many st ates it ’ s illegal t o operat[...]

19 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Oper ating the A T V aft er consuming alc ohol or drugs. WHA T CAN HAPPEN Consumpt ion of alcohol and/ or drugs c ould seriously aff ect operat or judgment. React ion time may be slower and operat or balance and perc eption could be affec ted. Consuming alc ohol and/or drugs before or while ope[...]

20 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Failur e to inspect the A T V before oper ating. Failure t o properly maintain t he A TV . WHA T CAN HAPPEN Poor m aintenance incr eases the pos sibility of an accident or equipment damage. HOW TO A VOID THE HAZA RD Always ins pect y our A TV bef ore each use t o make sure it ’s in safe oper [...]

21 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Failur e to use ext ra caut ion when operat ing the A TV on unfamiliar t errain. WHA T CAN HAPPEN Unfamiliar terr ain may contain hidden rocks, bumps, or holes t hat could c ause loss of cont rol or ov erturn. HOW TO A VOID THE HAZA RD T ravel slowly and use ext ra caution when oper ating on un[...]

22 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD T urning improper ly . WHA T CAN HAPPEN Im proper tur ns could cause los s of cont rol and lead to a c ollision or overt urn. HOW TO A VOID THE HAZA RD Always follow proper procedures for t urning as desc ribed in the owner ’s manual. Prac tice t urning at slow s peeds before at tempt ing to [...]

23 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Climbing hills im properly . WHA T CAN HAPPEN Impr oper hill climbing c ould cause los s of cont rol or overt urn. HOW TO A VOID THE HAZA RD Always f ollow proper procedur es for c limbing hills as desc ribed in the owner ’s manual. Always c heck t he terrain c arefully bef ore ascending any [...]

24 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD T raveling downhill impr operly . WHA T CAN HAPPEN Impr operly desc ending a hill could caus e loss of c ontrol or overt urn. HOW TO A VOID THE HAZA RD Always f ollow proper procedur es for t raveling down hills as des cribed in the owner ’s manual. NOT E: A special t echnique is requir ed wh[...]

25 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Impr operly cros sing hills and turning on hills . WHA T CAN HAPPEN Im properly cr ossing or t urning as hills could c ause loss of contr ol or overt urn. HOW TO A VOID THE HAZA RD N e v e ra t t e m p t t ot u r nt h eA T V around on any hill unt il you’ve mast ered the t urning tec hnique ([...]

26 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Stalling, rolling back wards or improper ly dismounting 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 for ward speed is lost: Keep your weight uphill. Apply t he brakes. Lock t he parking brak[...]

27 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Im properly operat ing over obst acles. WHA T CAN HAPPEN Oper ating over obs tacles c ould cause loss of cont rol or over turn. HOW TO A VOID THE HAZA RD Befor e operating in a new ar ea, check for obs tacles. Avoid operating ov er large obst acles such as rocks and fallen tr ees when possible.[...]

28 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Oper ating the A T V through deep or fast -flowing wat er . WHA T CAN HAPPEN T ires may f loat, caus ing loss of trac tion and loss of cont rol, which could lead t o an accident or overt urn. HOW TO A VOID THE HAZA RD Avoid operating t he A TV t hrough deep or fas t-f lowing water . I f it ’ [...]

29 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Operat ing this A TV wit h improper t ires, or with impr oper or uneven t ire pressur e. WHA T CAN HAPPEN Use of i mproper t ires, or operation of the A T V with im proper or uneven t ire pressur e, could caus e loss of c ontrol or accident . HOW TO A VOID THE HAZA RD Always us e the siz e and [...]

30 SAFE TY Operator S afety W ARNING POTENTI AL HAZARD Over loading the A TV or carr ying/t owing cargo improper ly . WHA T CAN HAPPEN Over loading and towing can c ause changes in vehic le handling, which could lead t o loss of contr ol or an accident . HOW TO A VOID THE HAZA RD Never ex ceed the st ated load capac ity f or this A T V . Cargo shou[...]

31 SAFE TY Operator S afety W ARNING Oper ating a damaged A TV can result in an accident with s erious injury or death. Aft er any over turn or ac cident, have a qualified serv ice dealer inspect the ent ire machine f or possible dam age, including (but not lim ited to) brakes, thr ottle and s teering systems. W ARNING Safe oper ation of t his ride[...]

32 FEATURES AND CONTROLS Engine E lectrical S witches W ARNING Act ivating t he override s witch while t he throt tle is open can c ause loss of cont rol, res ulting in sever e injury or deat h. Do not activ ate the over ride swit ch while the t hrott le is open. Mod e/Revers e Overri de S witch (1) - This veh icle is e quipped with a reve rse spee[...]

33 FEATURES AND CONTROLS W ARNING Operat ing an A TV wit h stic king or improper ly operating t hrott le contr ols could caus e an accident and lead t o severe injur y or death. Never s tart or operat e an A T V with a s ticki ng or improperly operat ing thrott le. Always c ontact y our dealer for serv ice if throt tle problems ar ise. Failur e to [...]

34 FEATURES AND 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 f rom HI to LO. NOT E: The lights won’t work unles s the key is in the ON posit ion and the auxiliar y shut -off swit ch is in the RUN pos ition. W ARNING Oper ating the A T V on str [...]

35 FEATURES AND CONTROLS Master Cylinder The brake f luid in t he ma ster cylinde r (1) , which is loca ted on the left handle bar , should be checke d before each ride. Th e flui d level can be seen through an indic ator window (2) on the top of the master cylinde r . This eye wil l appear dark whe n the fluid le vel is full. Whe n fluid needs to [...]

36 FEATURES AND CONTROLS Park in g Brake W ARNING Oper ating the A T V while the park ing brake is engaged could result in an acci dent and serious injury or deat h. Alway s check to be sure t he parking brak e is disengaged befor e operating. Setting the Par king Brake 1. Place the tra nsmission in park. 2. S queeze an d releas e the b rake leve r[...]

37 FEATURES AND CONTROLS Auxiliary Brake W ARNING Aggres sively applying t he auxiliary br ake when backing down a hill may c ause rear t ipover , which could r esult in ser ious injury or death. Use caut ion when applying the aux iliary brake. Do not aggress ively apply t he auxiliary brak e when going forward. T he rear wheels may sk id and slide[...]

38 FEATURES AND CONTROLS Automatic T ransm ission Gear S elector The transmission gea r selec t or (1) is locate d on the right side of the vehicle . H: High Gear L: Low Gear N: Neutral R: Rev er se P: Par k T o shif t into HIGH or P ARK, you must first apply the auxilia ry bra ke to activa te the high/park loc k-out mec hanism. Whe n shifting out [...]

39 FEATURES AND CONTROLS All Wheel D rive (A WD) S ystem Pol aris 4-wheel d rive A TVs are equipped w ith a unique , Po laris- exclus ive, On -Demand Al l Whe el Drive s ystem, which is acti vated b y the A WD swi tch (1) o n the right handleba r . When the s w i t c hi so f f ,t h eA T Vi si n two-w hee l drive at all times. When the switc h is on[...]

40 FEATURES AND CONTROLS In stru men t Clus ter Y our A TV is e quipped with a n instrument cluster that sen ses veh icle speed from the right front whe el. The instrume nt cluster measur es distanc e in mile s as we ll as hours of operation. It also include s a reve rse spee d limiter f unction tha t limits the A TV’ s speed to approxima tely 7-[...]

41 FEATURES AND CONTROLS In stru men t Clus ter Ride r Infor ma tion Center The r ider inf ormation ce nter is locate d in the instrument cluste r . All segmen ts will light up for 2.5 seconds at star t-up. NOT E: If the inst rument clust er fails to illuminat e, a bat tery over- voltage may have occur red and the inst rument clust er may have shut[...]

42 FEATURES AND CONTROLS In stru men t Clus ter Ride r Infor ma tion Center The r ider inf orma tion ce nter h as 4 standa rd modes: Mode 1 - Odometer Mode 2 - T ripmeter Mode 3 - T otal Service Hour s Mode 4 - T ac hometer The reve rse override button on the left handleba r is also the mode button . NOT E: If using the m ode button t o program the[...]

43 FEATURES AND CONTROLS In stru men t Clus ter Ride r Infor ma tion Center Diagnos tic Mode The diagnostic mode is for infor mational purpose s only . Pl e ase re t urn your A TV to your dealer for a ll major rep airs. As long as the gauge is in the diagnostic mode, the wrench icon will re main lit. T o lea ve the diagnostic mode , either shift th[...]

44 FEATURES AND CONTROLS In stru men t Clus ter Ride r Infor ma tion Center Diagnos tic Mode Screen 5: Programmable se rvice inter val The purpose of the progra mmable service inte rval is to provide the consumer a nd dealer with a conve nient reminde r for routine maintena nce. When your vehicle lea ves the factory , this feature is set at 50 hour[...]

45 FEATURES AND CONTROLS In stru men t Clus ter Ride r Infor ma tion Center Spe cial E FI Diagnos tic Mode The EFI diagnostic mode is for informa tional purposes only . Please see your Polar is dealer f or all major repair s. T o download blink codes (fa ilure code s) from the EFI module: 1. Place the t ra nsmission in P ARK, turn the engine off a [...]

46 OPERATION Fuel Safety W ARNING Gas oline is highly fla mm able and ex plosiv e under ce rta in conditi ons. Always exercis e extrem e caution whenever handling gasoline. Always refuel wit h the engine st opped, and out doors or in a well ventilat ed area. Do not sm oke or allow open f lames or spar ks in or near t he area where ref ueling is per[...]

47 OPERATION Br eak-In Period The bre ak-in period f or your ne w Polaris A TV is def ined as the first ten hours of opera tion, or the time it takes to use the first two full t a nks of gasoline. No single a ction on your pa rt is as impor tant as fo llowing the proce dure s for a proper bre ak- in. C ar eful tre atment of a new engine will result[...]

48 OPERATION Pr e-Ride Inspection W ARNING If a proper ins pection is not done befor e each use, s evere injury or deat h could result . Alway s inspect the vehic le before each us e to ens ure it’s in proper operat ing condition. Pre -Ride Check lis t Item Remarks See Page Brake system / lever t ravel Ensure proper oper ation 34, 78 Bra ke fluid[...]

49 OPERATION Star ting the Engi ne W ARNING Engine exhaus t cont ains poisonous car bon monoxide and can cause los s of cons ciousness r esulting in sev ere injury or deat h. Never r un an engine in an enclosed area. 1. Position the vehicle on a leve l surfac e with the transmission in P ARK. 2. Lock the park bra ke, sit on the vehicle a nd t urn t[...]

50 OPERATION Hauling Cargo Y our A TV ha s bee n designed to c arr y or tow a ce rtain a mount of load. Always re ad a nd understa nd the load distribution war ning labe ls on the vehi cle, an d never exceed t he weigh t capac ities outline d in the speci ficat ions s ectio n of the own er ’ s manual and on t he safety d ecals. Car go weight shou[...]

51 OPERATION Hauling Cargo W ARNING Hauling cargo im properly can alt er vehicle handling and m ay cause los s of cont rol or brak e instabilit y and result in serious injury or deat h. Alway s follow these prec autions when hauling cargo: REDUCE SPEED AND ALLOW GREA TER DI ST ANCES FOR BRAKING WHEN H AULING C ARGO. CARGO WE IGHT DIS TRIB UTIO N sh[...]

52 OPERATION Driving Safely Driving Pr ocedures 1. Sit upright with both feet on the f ootrests a nd both hands on the handleba rs. 2. Start the e ngine a nd allow it to war m up, then shift the tran smission into gea r . 3. Check your surr oundings and determine your path of travel. 4. Relea se the parking brake . 5. Slowly depre ss the throttle w[...]

53 OPERATION Driving Safely Making T urns Y our A TV is e quipped with a sol id rear axl e, whi ch driv es bot h rear wheels equ ally at al l times. This mea ns that the wheel on the outside of the turn m ust t ravel a greater di stance t han t he in side w heel when tur ning and the inside tire must slip tr ac tion slightly . T o turn, steer in th[...]

54 OPERATION Driving Safely Driving on Slippery S u rfaces When ever riding on slippery surfaces s uch as wet trai ls or loose grave l, or during freezing weather , fo llow t hese precaut ion s: 1. Slow down when enteri ng sl ippery areas . 2. Engage A WD bef ore whe els be gin to lose trac tion. 3. Mainta in a high lev el of alert ness , readi ng [...]

55 OPERATION Driving Safely T raveling Uphill Whe neve r tra veling uphill, follow these pr ecauti ons: 1. Always trave l straight uphill. 2. A void steep hills (25 _ ma ximum). 3. Keep both f ee t on the footre sts. 4. T ransfer your we ight forwa rd. 5. P roceed at a st eady rate of s peed and th ro ttle opening. 6. Remain a lert a nd be pre pare[...]

56 OPERATION Driving Safely Sidehilling W ARNING Impr operly cr ossing hills or t urning on hills can r esult in loss of contr ol or vehicle ov erturn, result ing in severe injur y or deat h. Avoid cross ing the side of a hill when possible. Follow proper procedur es as outlined in t he owner ’s manual. Sidehilling can be the most dangerous type [...]

57 OPERATION Driving Safely T raveling Downhill W ARNING Exces sive speed when t raveling downhill can c ause loss of contr ol and serious injury or death. Whe n trav eling downhill, follow these pr ecauti ons : 1. T ransfe r your weight to the rea r . 2. Drive str aight down the hill. 3. S low down . S queeze t he brake l ever gradually . W ARNING[...]

58 OPERATION Driving Safely T urning A round on a Hi ll W ARNING Im proper hill climbing pr ocedures could c ause loss of contr ol or overt urn and result in serious injury or deat h. Avoid climbing st eep hills (25 _ maximum). Use ext reme caut ion when operating on hills , and follow pr oper operat ing procedures out lined in the owner ’ s manu[...]

1 59 OPERATION Driving Safely Dr iving Through W ater Y our A TV c an oper ate through wate r 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 wate r: 1. Deter mine wate r depths and current before crossing. 2. Choose a crossing where both banks have gradua l inclines. 3[...]

60 OPERATION Driving Safely Driving Over Obstacles Be alert ! Loo k ahead and learn t o read the t errain you ’re traveli ng on. Be con stant ly al ert for hazards s uch as log s, ro cks and l ow hangi ng branch es. W ARNING Severe injur y or deat h can result if your vehicle com es in contac t with a hidden obst acle. Not all obs tacles ar e imm[...]

61 OPERATION Driving Safely Driving in Rever se Fo llo w these precaut ion s when operat ing i n reverse: 1. Always avoid back ing downhill. 2. Back slowly . 3. Wh en in reverse, apply the brake s lightly for stopping. 4. A void t urning a t sharp an gles i n reverse. 5. Never open the throttle sudde nly while bac king. W ARNING Failur e to use cau[...]

62 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on an inc line if possible . If it’ s unavoidable, follow thes e precaut ions : 1. T urn the engine of f. 2. Place the tra nsmission in park. 3. Set the parking brake. 4. Always block the rear whe els on the downhill side as shown.[...]

63 EMISSION C ONTR OL SYST EMS Noise Em ission Contr ol System Do not modify the engine, intake o r exhaust components, as doing so may af fec t complianc e with state and loc al noise level re quire ments. Spar k Arr estor Y our Polaris vehicle has a spa rk arre stor that wa s tested a nd approve d in accordance wi th th e USDA For es t Servi ce S[...]

64 MAINTENANCE AND LUBRICATION Accessor ies Auxiliar y power outlets provide 12V power for oper ating accesso ries such as ha nd held spot lights. See your Pola ris dea ler . Per iodic Maintenance Chart Care ful periodic ma intenan ce will help keep your vehic le in the safest, most relia ble c ondition. Inspection, adjustme nt and lubr ica tion of[...]

65 MAINTENANCE AND LUBRICATION Per iodic Maintenance Chart Perfo rm all servi ces at whichev er maint enance int erval is reached firs t. Item Maintenance I nterval (whic hever c omes fir st) Remarks Hours Calendar Miles (Km) J Steering -- P re-Ride -- Mak e adjustments as need- e d S e e P r e R i d e C h e c k l i s t " Front s uspens ion --[...]

66 MAINTENANCE AND LUBRICATION Per iodic Maintenance Chart Item Maintenance I nterval (whic hever c omes fir st) Remarks Hours Calendar Miles (Km) " Transmis sion oil 25 H Monthly 250 ( 400) Inspec t lev el; change year ly " E Engine breather filter (if equipped) 25 H Monthly 250 ( 400) Inspec t; c lean if needed " Gener al lubric at[...]

67 MAINTENANCE AND LUBRICATION Per iodic Maintenance Chart Item Maintenance I nterval (whic hever c omes fir st) Remarks Hours Calendar Miles (Km) J E Spark plug 100 H 12 M 1000 (1600) Inspect ; replace as needed J E Ignition Timing 100 H 12 M 1000 (1600) Ins pect " Wiring 100 H 12 M 1000 (1600) I nspec t for wear, routing, sec urity ; apply d[...]

68 MAINTENANCE AND LUBRICATION Per iodic Maintenance Recor d Use th e foll owing chart t o record p eriodi c main tenance. Maintenance In terval Perfo rmed Ser vicing Date Ser vic ing Dealer or Pe rs on Remarks[...]

69 MAINTENANCE AND LUBRICATION Lubri cation Guide Chec k and lubric ate all compone nts at the inte rva ls outlined in the Periodic Mainte nanc e Chart beginning on page 64. Items not listed in the char t should be lubricated at the Ge nera l Lubric ation interva l. Lubri cati on Guide Ke y " More of ten under severe use , such as we t or dust[...]

70 MAINTENANCE AND LUBRICATION Pr emium 4 Synthetic Lubr icant Polaris Pre mium 4 All Season synthetic engine oil has bee n spec ially formula t e d for use in Polaris 4-cyc le engines. It’ s a fully synthetic, high perf ormance , multi-viscosity oil designe d to provide the ultimate in l ubri catio n perform ance and p rotecti on. S ee page 10 7[...]

71 MAINTENANCE AND LUBRICATION Oil Level The oil dipstick a nd fill tube ( 1) is loca ted on the e ngine a nd is accessi ble o n the l eft si de of t he A TV . 1. Position the A TV on a leve l surf ace. 2. Start the engine and let it idle for 20-30 sec onds, then stop the engine. 3. L ift t he lever l ock (2) t o remo ve the dipstick. W ipe it dry [...]

72 MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION Hot oil c an cause serious burns t o skin. Do not allow hot oil to come int o contac t with s kin. Alwa ys change the oil and filte r at the interv als outlined in the Periodic Maintena nce Chart beginning on page 64. Always cha nge the oil filter whenev er changi ng oi l. 1. Position the[...]

73 MAINTENANCE AND LUBRICATION T ransmission Oil Always che ck and c hange the tran smission oil at the interv als outline d in t he P eriodi c Main tenan ce Chart beginning on page 64. Maintain the tran smission oil leve l at the bottom of the fill plug hole (1). W e rec ommend the use of Polaris Pre mium AGL Sy nthet ic Gearcase L ubrican t. S ee[...]

74 MAINTENANCE AND LUBRICATION Front Gear case Oil Always check an d change t he fron t gearcase o il at the i nterv als outlined in the Periodic Mainte nanc e Chart beginning on page 66. Mainta in the oil level even with the bottom of the fill hole threads (1). W e re comme nd the use of Polaris Premium De mand Drive H ub Fluid. Use of other oils [...]

2 1 3 75 MAINTENANCE AND LUBRICATION Rear Gear case Oil The rear g earcase fil l pl ug (1) i s lo cated on the rear o f the gearcase. Al ways check an d chang e the rear g earcase oil at the inter vals outline d in the Peri odi c Maint enance C hart beginning on page 64. Mai ntai n the rear g earcase oil level ( 2) eve n with the bottom of the fill[...]

76 MAINTENANCE AND LUBRICATION Engine C ooling System Radiator Coolant Level T o ensure that the coola nt maintains its ability to protect the engine, we recomm end th at the sy stem b e c om pletel y drain ed every two years an d a fresh m ixt ure of ant ifreeze and water ad ded. P olaris recom mends the use o f Pol aris P remi um 60 /40 anti -fre[...]

77 MAINTENANCE AND LUBRICATION Engine C ooling System Coolant Level The r ecove ry bottle (1) is loca ted on the left sid e of th e machi ne. T o acces s th e rec overy bottle, remove the left side pane l as outlined on pa ge 81. Mainta in the coola nt l e vel betw ee n the minimum and maximum mar ks on the bottle (whe n the fluid is cool). Add coo[...]

78 MAINTENANCE AND LUBRICATION Br akes The front and re ar bra kes are hydr aulic disc br akes, activa t ed by moving the single brake leve r toward the handle bar . These bra kes are self- adjusting. The fo llowi ng check s are recom mended to k eep the b rake sys tem i n good opera ting condition. Check mor e ofte n i f br ake s are used heavily [...]

79 MAINTENANCE AND LUBRICATION Br akes 2. C heck t he brake s yst em for fl uid l eaks. 3. C heck t he brakes for ex cessiv e travel or spongy fee l. 4. C heck th e frictio n pads for wear , damage a nd l oose ness. 5. C heck th e securit y and surface condition of the disc. NOT E: Replace brake pads when they a r ew o r nt o3 / 6 4 ″ (.1 cm). Au[...]

80 MAINTENANCE AND LUBRICATION T oe Ali gnment W ARNING Sever e injury or deat h can result from improper t oe alignment and adjustm ent. Do not at tempt to adjus t tie r od alignment. All t ie rod adjustm ents s hould be perform ed by an authoriz ed Polaris dealer. Use the following proce dure to chec k the toe alignment of the vehicle. The rec om[...]

81 MAINTENANCE AND LUBRICATION Side P anel Rem oval 1. Remove the sea t. 2. Gras p th e rear of th e side p anel near the rear cab . W it h a firm motion, pull the pane l outward to disengage the side pane l from the grommet. 3. Pull the panel downwar d and r ear ward to r emove it f rom the A TV . 4. Reinstall the side panel by rever sing the remo[...]

82 MAINTENANCE AND LUBRICATION W ARNING Operat ing your A T V with worn t ires, improperly inflat ed tires , non-st andard tires or im properly inst alled tires will affect v ehicle handling and could caus e an accident r esulting in ser ious injury or death. Maint ain proper tir e pressure as described on t he decal on your A TV and in t he owner [...]

83 MAINTENANCE AND LUBRICATION Wheel Installation W ARNING Im properly inst alled wheels can adver sely affect tir e wear and vehicle handling, which can r esult in ser ious injury or deat h. Always ens ure that all nuts are tor qued to specif ication. Do not serv ice axle nuts that have a cot ter pin inst alled. S ee your Polaris dealer. 1. Place [...]

84 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service 1. R emov e the s eat, releas e the ai r box cover clips, and r emove the air box cover . 2. Loosen the c lamp a nd re move the filte r . 3. Remove the fa bric type pre-f ilter (1) f rom the main filte r (2) . W ash the pre -filter in soa py wa ter , then rinse and let dry . 4. Reins[...]

85 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a ha logen lamp, don’ t t ouch the lamp with bare finger s. Oil from your skin le aves a r esidue, c ausing a hot spot that will shorten the life of the la mp. W ARNING Poor light ing while driving can r esult in sev ere injury or deat h. Headlight and t aillight lenses become dirt y during n[...]

86 MAINTENANCE AND LUBRICATION Lights High Beam Adjus tment The h eadli ght b eam can b e adjus ted slightly upward or downwar d. Use the following proce dure to make the adjustment. 1. Position the vehicle on a leve l surfac e with the hea dlight approxima tely 25 ft. (7.6 m) from a w all. 2. Measur e the distanc e from the floor to the cente r of[...]

87 MAINTENANCE AND LUBRICATION Lights Headlight Housin g Replacement 1. Remove the two screws on the lower front corner s of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rea r of the pod. 3. Lift the pod cover and disconne ct the speedome ter harn esses fr om th e speedo meter . 4. Unplug the hea dlamp f rom the wiri[...]

1 1 2 2 1 88 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Rem oval / Installation 1. T urn the back of the hea dlight harne ss (1) counter clockwise and pull the harness asse mbly away from the h eadli ght asse mbly . 2. Remove the he adla mp and install the new hea dlamp. 3. Reinstall the harne ss assembly into the headlight asse mbly . 4. T [...]

89 MAINTENANCE AND LUBRICATION Spar k Plugs S Use RC 7YC spark plugs. S Proper ele ctrode gap is .035 ″ (.90 mm). S Spark plug torque is 18 ft. lbs. (24 Nm). CAUTION Using non-r ecommended spar k plugs can res ult in serious engine damage. Always use Polaris -recom mended spark plugs . Spark plug c ondition i s indica tive of e ngine operation. T[...]

90 MAINTENANCE AND LUBRICATION V e h ic le I mmers ion CAUTION If your v ehicle becomes im mersed, major engine damage c an result if t he machine is not thor oughly inspect ed. T ake t he vehicle t o your dealer bef ore st arting t he engine. If it’ s impossible t o take your A TV to a dealer be for e starting it, follow the steps outlined below[...]

91 MAINTENANCE AND LUBRICATION Spar k Arr estor W ARNING Failur e to heed the f ollowing warnings while ser vicing the s park arres tor could r esult in ser ious injury or deat h. Do no t perform service on the sp ark arrestor wh ile the system is hot. Exhaust syst em tem peratures ca n reach 1000 ° F . A llow component s to c ool sufficient ly be[...]

92 MAINTENANCE AND LUBRICATION PV T System The basic oper ation of the Polaris PVT system is depe ndent on engine speed and v ehicle t orque req uirem ents . As en gine s peed in creases, th e forc e exer ted on the movable drive shea ve by the flyweights also incre ases. This, in turn , incre ase s the amount of pinch a p p l i e dt ot h e drive b[...]

93 MAINTENANCE AND LUBRICATION PV T System W ARNING Failure t o comply wit h the inst ruct ions in this war ning can result in sever e injury or deat h. Do not modify any component of th e PVT syst em. Doing so may reduce it s st rength so t hat a f ailure may occ ur at a high speed. The PVT syst em has been precisio n balanced. Any m odification w[...]

94 MAINTENANCE AND LUBRICATION Batter y W ARNING Im properly connec ting or disc onnecting bat tery c ables can res ult in an explosion and c ause serious injur y or death. W hen remov ing the batt ery , always disconnect the negat ive (black ) cable fir st. W hen reinstalling t he batt ery , always connect the negative ( black) c able last. Batt e[...]

95 MAINTENANCE AND LUBRICATION Batter y Batter y Storage Whe neve r the vehicle is not used for a per iod of three months or more, remov e the b attery fro m th e vehicl e, en sure th at it ’ s ful ly charged, and st ore it ou t of the su n in a cool, dry p lace. Ch eck batt ery volt age each mo nth du ring s torage and rech ar ge as needed t o m[...]

96 MAINTENANCE AND LUBRICATION Batter y Batt ery Chargin g NOT E: Always v erify batt ery condit ion before and 1-2 hour s aft er the end of c harging. Stat e of Charge Vo l t a g e Act ion Char ge T ime* (Us ing constant c urrent char ger @ standar d amps spec ifi ed on top of battery ) 100% 12.8- 13.0 v ol ts None, check at 3 mos. f rom date of m[...]

97 MAINTENANCE AND LUBRICATION Cleaning and S torage See page 107 for the par t numbers of Polaris products. Cleaning th e A TV Keep ing your A TV clea n will not only improve its appe aranc e but it ca n also ex tend the lif e of var ious compone nts. W ith a few precautions , your A TV can be cleaned m uch like an automobil e. W ashing t he A TV [...]

98 MAINTENANCE AND LUBRICATION Cleaning and S torage Sto rag e Tips CAUTION Star ting t he engine during the st orage period will dist urb the prot ective f ilm creat ed by fogging and dam age could occur . Nev er star t t he engine during the st orage period. Clean t he Exterio r Make ne cessary r epa irs and the n clean the A TV thoroughly with m[...]

99 MAINTENANCE AND LUBRICATION Cleaning and S torage Sto rag e Tips Fog the Engi ne 1. T rea t the fue l system with Pola ris Car bon Clean , following the instructions on the ca n. Run the engine for seve ral minutes so the Carb on Cl ean reaches the i nject ors. T urn t he engi ne off. 2. Remove the s pa rk plugs and a dd 2-3 table spoons of Prem[...]

100 MAINTENANCE AND LUBRICATION Cleaning and S torage Chr ome Wheel Care (i f equipped) Pro per maint enance will p rotect ch rome wheels from co rrosio n, preserv e wheel l ife and en sure a “li ke new” app earance for m any years . 1. W ash ch rome rims fr eque ntly . Use a mild deter gent to remove any salt, dirt, mud or grime . Never use ab[...]

101 ADJUSTMENTS Cam ber and Caster The cambe r and ca ster ar e non-a djustable . Rear S pring The rea r shock absor ber spring is adjuste d by rota ting the adjuste r (1) eit her clo ckwis e or counter clockwise to incre ase or decrease s prin g tens ion . NOT E: Accessory sp ring s are available thr ough your Polaris dealer. Handlebar s W ARNING [...]

102 ADJUSTMENTS Throttl e Body/Idle R PM Idle RPM is preset by the manufac t ure r . If the engine idle speed is not satisfa ctory , please se e your Polaris dea ler fo r adjustment. Throttl e Cable Freepl ay Throttle c able fre epla y is adjusted at the handleba r . 1. Slide the boots (1) off the inline ca ble adjuster slee ve (2). Loosen the adju[...]

103 TROUBLE SHOOTIN G Drive Belt and Cover Pr o blems Po ssibl e Cause Soluti on Dri ving the A TV ont o a pick up or tall trailer in high r ange Shif t tr ansm is sion t o low ra nge dur ing l oading of the A TV to pre vent be lt bur ning. Sta rti ng out going up a steep inclin e Whe n s ta rti ng out on an i ncli ne, us e l ow r ange or di s- mou[...]

104 TROUBLE SHOOTIN G Contact your Polaris dea ler for se rvice if you’ re unable to identif y solutions using the following c har ts. Engine Doesn’t T urn Over Possi ble Ca use Sol ution Tripp ed circu it break er Reset th e b reaker Lo w battery v oltag e Rec har ge ba tte r y to 12. 8 VDC Loose ba tte ry conne ct ions Ch eck all conn ectio n[...]

105 TROUBLE SHOOTIN G Engine Backfires Possi ble Ca use Sol ution W eak s par k fr om spa rk plugs In spect, clean and /or replace spark p lug s Inco rrect spark plu g g ap or heat rang e Set gap t o spec s or r epl ac e plugs Old or non-r ec omme nded fue l Re pla ce wit h new fue l Inco rrectly installed sp ark plu g wires Se e your Pola ris de a[...]

106 TROUBLE SHOOTIN G Engi ne Stops or Loses P ower Possi ble Ca use Sol ution Out of fuel Refu el, cycle key to O N positio n three ti mes f or 5 sec onds each , then start Kinke d or plugged fue l vent li ne In spect an d rep lace W ater presen t in fu el Repl a ce wi th new fuel Foule d or def ec ti ve spa rk pl ugs Insp ect, clean and/ or repla[...]

107 POLARIS PRODUCTS Part No. Descri pti on Engine Lubr icant 2870791 Fogging Oi l (12 oz. Aerosol ) 2871281 Premi um 4 Syntheti c 0W -40 ( 4-Cycle) Engine Oi l ( qt. ) 2871844 Premi um 4 Syntheti c 0W -40 ( 4-Cycle) Engine Oi l ( gal. ) Gearcase / T ransmi ssion Lubricant s 2873602 Premi um AGL Synthet ic Gear case Lube (qt. ) 2873603 Premi um AGL[...]

108 SPECIFICA TIONS SPORT SMAN 700 EFI Gro ss V eh icle W eigh t 1240 lbs . (563 kg) Fu el Cap acity 4. 13 ga l. (15. 6 l ) Engine Oi l Capa ci ty 2q t s . ( 1 . 9l ) Co olan t Cap acity 3 . 2q t s .( 3l ) Fro nt R ack/S torag e Bo x C apacity 100 lbs . (45 kg) Rear R ack C apacity 200 lbs . (91 kg) Hit ch T ongue Capa cit y 15 0 lbs. (68 k g)(R ea[...]

109 SPECIFICA TIONS SPORT SMAN 700 EFI Shif t T ype Side Le ver (H/ L/N/R/ P) Gear R edu ction - L ow 7.49: 1 Gea r Reduc ti on - Rever se 5.1 1:1 Gea r Reduc ti on - High 2.70: 1 Driv e Ratio - F ron t: 3.82:1 Driv e Ratio - F inal 3. 10:1 T ir es - Front P o l a r i sP X T2 6x8-1 2( 5p s i ) Tires - Rear P o l a r i sP X T2 6x1 1- 1 2( 5p s i ) F[...]

11 0 WARRANTY LIM ITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of the Polaris All T errain V ehicl e (A TV) agains t defect s in m aterial or wor kmans hip. Polaris also give s a one year limited wa rranty on the final drive cha i n for fa ilure due to defe cts. This war[...]

111 WARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIM IT A T IONS OF W ARRANTIES AND REM EDIES The Polar is limited wa rranty exc ludes any failur es that a re not c ause d by a def ec t in mater ial or workma nship. This warranty doe s not cove r accid ental d amage, no rmal wear an d tear , abu se or i mprop er handl ing . This warr anty also doe s[...]

11 2 WARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIM ITED TO THE IMPLIED W AR RANTIES OF MERC HANT ABILITY AND FITNES S FOR A P AR TICULAR PUR POSE) AR E LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY P ERIOD. POLARIS F UR THER DISCLAIMS ALL EXPR ESS W AR RANTIES NOT ST A TED IN THIS W AR RANTY . So me states do not all ow limitation[...]

11 3 WARRANTY Exported V ehicles EXCE PT WHE RE SPECI FICA LL Y REQU IRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BULLETIN COVER AGE ON THIS VEHICL E IF IT IS SOLD OUTS IDE THE COUNTR Y OF THE SELLING DEALER ’S AUTHORIZED LOCA TION. Thi s pol icy does not app ly to v ehicl es that h ave received au thori zati on for e xport from Polaris I ndu[...]

11 4 WARRANTY Exported V ehicles How to Ge t Ser vice If Purchased From A Private Party : If you purcha se a Polaris product fr om a private citiz en outside of the country in whic h the vehic l e was or iginally purc hase d, all warr anty cover age will be denied. Notic e If your vehic le is registere d outside of the country where it was pur- cha[...]

11 5 INDEX A Accesso ries 64 ................... ADJ USTMENTS 101- 102 .......... Ag e Restrictio ns 11 ............... Air F ilter Serv ice 8 4 ............... All Whe el Dr ive 39 ............... Au tom atic Transmissio n 3 8 ......... Au xiliary B rake 7 9 ............... AW D 3 9 ........................ B Bat ter y 94-96 .................... B[...]

11 6 INDEX O Odome ter 42 .................... Oil C hange 72 ................... Oil F ilter Ch ange 72 .............. Oil L evel 71 ..................... OPERA TIO N 46-62 ............... Op erator S afety 11-3 1 .............. Ov erride S witch 32 ............... P Park ing B rake 36 ................. P a r k i n go na nI n c l i n e 6 2 .......[...]