Polaris 400 H.O. manual

1 WELCOME Thank you for purchasin g a Polaris vehicl e, an d welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excellence for a l[...]

2 POLARIS and POLARIS TH E W A Y OUT are registered t rademarks of Polaris Indus - tries Inc. Copyright 2007 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discrep[...]

3 T ABLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F eatures and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Emission Control Systems . . . . . . . . . . . . . [...]

4[...]

5 KNOW Y OUR VEHICLE As the operator of the vehicle, y o u are responsible for your persona l safety , the safety of others, and the protectio n of our enviro nment. Read and understand your owner's manu al, which includes valuable informa- tion about all aspe cts of your vehicle, incl uding safe operating pro ce- dures. V ehicle Identificatio[...]

6 SAFETY Safety Decals and Locations W arning decals have been placed o n the A TV for yo ur protection. Read and follow the instructions of the de cals on the A TV carefully . If any of the decals depicted in this manual dif fer from the d ecals on your A TV , always read and follow the instruc tions of the decals on the A TV . If any decal become[...]

7 SAFETY Safety Decals and Locations Discretionary W arning WARNING • Never operate this A T V on HILLS steeper than 25 degrees 25 ° . T o prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually . • REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. T o prevent flipover , avo[...]

8 SAFETY Safety Decals and Locations “No P assenger” W arning WARNING NEVER ride as a passenger . Pa ssengers can cause a loss of control, resulting in SEVERE INJURY or DEA TH. 7172566 Age 16 W arning WARNING Operating this A TV if you are und er th e age of 16 increa ses your chance of severe injury or death. NEVER operate this A TV if you are[...]

9 SAFETY Safety Decals and Locations Rack W arning, F ront and Rear WARNING • DO NOT TOW FROM RACK OR BUMPER. V ehicle da mage or tipover may result causing severe injury or deat h. T ow only from tow hooks or hitch. • Max Rack Loads: Front 70 lbs. (32 kg) Rear 100 lbs. (46 kg) 7173740 Reverse Override W arning WARNING Pushing reverse override [...]

10 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort and to redu ce the chance of in jury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in th[...]

11 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE ) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make[...]

12 SAFETY Operator Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. WAR N I NG F ailure to follow the warnings contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be haza rdous to operate. This vehicle han- dles differently tha[...]

13 SAFETY Operator Safety Safety T raining A TV safety t raining is a top priority for Polaris. Wh en you purchased your new A TV , your dealer instructed you on the autho rized A TV RiderCourse sm ava ilable to you and you r e ligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and[...]

14 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safe ty alert symbol , on your vehicle or in this manual, ale rts you to the potential for injury .[...]

15 SAFETY Operator Safety • Read this manual and all labels careful ly , and follow the operating procedures described. • Never operate an A TV without prop er instruction. T ake a training course. Purchasers of a new Polari s A TV and their eligible family members are entitled to take the A TV Rider Course sm . Contact A TV Enrollment Express [...]

16 SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfa- miliar terrain. Be alert to changing terrain conditions. • Never operate on excessively ro ugh, slippery , or loose terrain. • Always follow proper turning proce dures as described in this manual . Practice turning at low speeds befo re attempting t[...]

17 SAFETY Operator Safety • Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. • Always be careful of skidding or sliding. On slip pery surfaces like ice, travel slowly [...]

18 SAFETY Operator Safety FOR MORE INFORMA TION ABOU T A TV SAFETY , call the Con- sumer Product Safety Commission at 1- 800-638-2772, or visit www .cpsc.gov , visit www .atvsafety .org, or call Polaris at 1- 800-342- 3764. Equipment Modifications W e are concerned for the safety of our customers and for the general public. Therefore, we strongly r[...]

19 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating this A TV wi thout proper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if th e operator does not know how to operate the A TV properly in different situ ations and on differ ent types of terrain. HOW TO A VOID THE HAZARD Beginning and inexperienced operato[...]

20 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Carrying a passe nger on an A TV . WHA T CAN HAPPEN Carrying a passenger greatly reduces the oper- ator's ability to balance and control the A TV , which could cause an accident and injury to the operator and/or passen ger . HOW TO A VOID THE HAZARD Never carry a passenger . The purp ose of[...]

21 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating this A TV on publi c streets, roads or highways. WHA T CAN HAPPEN The A TV could collid e with another vehicle. HOW TO A VOID THE HAZARD Never operate the A TV on any public street, road or highway , incl uding dirt and gravel roads. In many states it's illegal to operate A TVs on[...]

22 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating the A TV after consuming alcoh ol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drugs could seri- ously affect operator judgment. Reactio n time may be slower and operator balance and per- ception could be a ffected. Consuming alcohol and/or drugs before or whi le operating [...]

23 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHA T CAN HAPPEN Attempting stunts increa ses the chance of an accident, including an overturn. HOW TO A VOID THE HAZARD Never attempt wheelies, ju mps, or other stunts. Avoid exhibition driving. WAR N I NG POTENTIAL HAZARD F ailure to inspect the A T[...]

24 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHA T CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection fro m the A TV . If the operator's foot is not firmly planted on the footrest[...]

25 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD F ailure to use extra caution when operating on excessive ly rough, slip- pery or loose terrain. WHA T CAN HAPPEN Operating on exce ssively rough, slip- pery or loose terrain could cause loss of traction or loss of co ntrol, which could result in an accident or over- turn. HOW TO A VOID THE HAZA[...]

26 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating on exce ssively steep hills. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZARD Never operate on hills too steep for the A TV or for your abilities. Never o perate the A TV on hills steeper than 25 degrees. WAR N I NG POTENTIAL HAZARD Climbing hills improperly . WHA T [...]

27 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD T raveling downhill imprope rly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking w[...]

28 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill. Apply the brakes. Lock the parking brake when fu[...]

29 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Improperly operating over obstacles. WHA T CAN HAPPEN Operating o ver obstacles c ould cause loss of contro l or overturn. HOW TO A VOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidab[...]

30 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating the A TV through dee p or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or o verturn. HOW TO A VOID THE HAZARD Avoid operating the A TV through dee p or fast-flowing water . If it's unavoidable [...]

31 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating this A T V with improper tires, or with improper or uneven tire pres- sure. WHA T CAN HAPPEN Use of improper tires, or operation of the A TV with improp er or uneven tire pressure, could cause loss of control or accident. HOW TO A VOID THE HAZARD Always use the size and type of tires s[...]

32 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Overloading the A TV or carrying/towing cargo improperly . WHA T CAN HAPPEN Overloading and towing can cause change s i n vehicle handling, which coul d lead to loss of control or an accident. HOW TO A VOID THE HAZARD Never exceed the stated load capacity for this A TV . Cargo should be p roperl[...]

33 SAFETY Operator Safety WAR N I NG Operating a dama ged A TV ca n result in an accident with seri ous injury or death. After any o verturn or accident , have a qualified se rvice dealer inspect the entire machine for possible damage, includin g (but not limited to) brakes, throttle and st eering systems. WAR N I NG Safe operation of this rider-ac[...]

34 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limi ter sy s t em .T o gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on. This switch is also used to toggle through t[...]

35 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engi ne quickly . The engine will no t start or run when the switch is of f. NOTE: Both the main sw itch and the engine stop switch will shut off all electri- cal power to the vehi cle, includi ng lights. Main Key Switch U[...]

36 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle move- ment are controlled by pressing the throttle lever . The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This A TV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck thr[...]

37 FEA TURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the fro nt an d rear brakes. These brakes are hydraulically activ ated disc type brakes tha t are activat ed by only one lever . Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any spon[...]

38 FEA TURES AND CONTROLS Pa r k i n g B r a k e Locking the P arking Brake 1. Place the transmission in gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o rele ase the parking brake lock, squeeze and release the brak[...]

39 FEA TURES AND CONTROLS Auxiliary F oot Brake The auxili ary brake syst em is intend ed to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. The auxili ary foot brake is located on the inside of the right footrest. Operate this brake with your right foot. NOTE: If the rear wheels slide while[...]

40 FEA TURES AND CONTROLS Choke The choke assists in s tarting a cold engine. Refer to the engine starting procedure on page 50 for correct ch oke and throttle settings during start- ing. Fu e l T a n k C a p Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gaso- line with a minimum pump octane number of 87=(R+ M[...]

41 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicl e. H: High Gear N: Neutral R: Reverse Whenever the A TV is left unattended, always place the transmission in gear and lock the parking brake. CA UTION Shifting gears with the engin e speed above idle or while th [...]

42 FEA TURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine , use the recoi l starter . Follow the starting procedures on page 50, crank ing the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly . 2. Pull slowly so you can feel the engine strokes. NOTE: The rop[...]

43 FEA TURES AND CONTROLS All Wheel Drive (A WD) System The All Whee l Drive syst em is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive. When in A WD, the demand drive unit will automatically engage any time the rear wheels lose tractio[...]

44 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the A TV's speed to approximately 7-9 mph. Refer to p[...]

45 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 3 seconds at st art-up. 1. Gear Indicator - This indicator displays gear shifter position. N = Neutral (Green) R = Reverse (Amber) 2. Engine Hour Display Indicator 3. Speedometer [...]

46 OPERA TION F uel Safety WAR N I NG Gasoline is h ighly flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is perf[...]

47 OPERA TION Break-In P eriod The break-in period for yo ur new Polaris A TV is the first ten hours of operation, or the time it takes to use the first two full ta nks of gasoline. No single action on your part is as important as following the proce- dures for a proper break-in. Careful treatment of a new engine and drive components will result in[...]

48 OPERA TION Break-In P eriod Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 40. 2. Check the oil level on the dipstick. See page 75. Add oil if neces- sary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en area that allows room to famil- iarize yourself with vehi cle oper[...]

49 OPERA TION Pre-Ride Checklist WAR N I NG If a proper inspection is not done befor e ea ch use, severe i njury or death could result. Always inspect the vehicl e before each use to ensure it's in proper operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 37 88 Brake fluid Ensure proper level 86 Auxiliary[...]

50 OPERA TION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. NOTE: The starter in terlock will prevent the engine from starting if the trans- mission is in gear and the brake is not enga ged. 4. T urn the fuel valve on. 5. Sit on the vehicle. NOTE: Do not use the chok[...]

51 OPERA TION Starting the Engine 8. T urn the ignition key past the ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the engin e sta r ts . 9. If the engine does not start, return the key to the OFF position and wait five seconds before attemptin g to start again. Activate the starter f[...]

52 OPERA TION Hauling Cargo Y our A TV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities out lined in the specifi- cations section of the owner's manual and on the safety decals. Cargo wei ght should be even ly distr[...]

53 OPERA TION Hauling Cargo WAR N I NG Hauling cargo imprope rly can alter vehicle handl ing and may cau se loss of control or brake instability and result in serious inju ry or death. Always follow these precautions when haul ing cargo: REDUCE SPEED AND ALL OW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO . CARGO WEIGHT DISTRIBUTI ON should b[...]

54 OPERA TION Driving Safely Driving Procedures 1. W ear protective ridin g gear . See page 10. 2. Sit upright with both feet on th e footrests and both hands on the handlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check your surroun dings and determine your path of travel. 6. Release the parking br[...]

55 OPERA TION Driving Safely T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly . T o turn, steer in the directio[...]

56 OPERA TION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather , follow these precautions: 1. Slow down when enter- ing slippery areas. 2. Engage A WD before wheels begin to lose traction. 3. Maintain a high level of alertness, reading the trail and avo[...]

57 OPERA TION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Keep both feet on the footrests. 4. Shift your weight uphill. 5. Proceed at a ste a dy rate of spee d an d throttle opening . 6. Remain al ert and be prepar ed to take emer gency action[...]

58 OPERA TION Driving Safely Driving on a Sidehi ll (Sidehilling) Sidehilling can be dangerou s and should be avoided if at all possible. If you encounter a situation where si dehilling is necessary , follow these precautions: 1. Slow down. 2. Shift your weight uphill. 3. Keep your feet on th e fo otrests. 4. Steer slightly into t he hill to mainta[...]

59 OPERA TION Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Shift your weight uphill. 2. Drive straight downhill. 3. Slow down. 4. Squeeze the brake lever gradually . NOTE: Before operating yo ur A TV , learn ho w to use the auxiliary br ake for emergency situations (if singl e-lever brakes become inoperab le).[...]

60 OPERA TION Driving Safely T urning Around on a Hill (K - T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m)[...]

61 OPERA TION Driving Safely T urning Around on a Hill (K - T urn) 1. S top and lock the parking brake wh ile keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hicle, or on the left if the vehi- cle is pointin g straight uphill. 4. Staying uphill of the vehicle, turn t[...]

62 OPERA TION Driving Safely Driving Through W ater Y our A TV can operate through wa ter with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through wat er: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly [...]

63 OPERA TION Driving Safely Driving Through W ater After running the vehicle in water , it's critical to have it serviced as out- lined in the maintenance chart. See page 68. The following areas need special attention: engine oil, transmi ssion oil, front and rear gearcases, and all grease fittings. NOTE: Avoid operating the vehicle through d[...]

64 OPERA TION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and lo w hanging branches. WAR N I NG Severe injury or death can result if your vehicle comes in contact with a hid- den obstacle. Not all obstacles are immediately visi[...]

65 OPERA TION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the bra kes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . NOTE: Y o ur Polaris A [...]

66 OPERA TION Driving Safely P arking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Always block the rear wheels on the do wnhill side. 5. T urn the fuel valve off.[...]

67 EMIS SION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark a rrestor that was tested and qual[...]

68 MAINTENANCE P eriodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main ten a nc e ch art. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals th[...]

69 MAINTENANCE P eriodic Maintenance Chart Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warrant y but may affect emissions.) Q Have an authorized Polaris dealer perform these services. WAR N I NG Imprope[...]

70 MAINTENANCE P eriodic Maintenance Chart Perform all services at whichever main tenance interval is reached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calen[...]

71 MAINTENANCE P eriodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc. Carburetor float bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage Q E Throttle Cable/ ETC Switch 50 H 6 M 500 (800) I[...]

72 MAINTENANCE P eriodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q Clutches (drive and driven) 100 H 12 M 1000 (1600) Inspec[...]

73 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 68. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS P erformance Synthetic 2W-50 See page 74. Brake Fluid DOT 4 Only See pa[...]

74 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's re commendations fo r ambient tempera- ture operation[...]

75 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the left front tire. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Clean away all dirt and debris on the oil tank or in the wheel well area. 5. Star t the engine. Allow it to idle for 30 seconds. Stop the engi ne.[...]

76 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginn ing on page 68. T o change the oil properly , always drain the oil tank and change the oil filter . NOTE: If oil contamination (water , mud, metal shavings) is suspected in the engine sump, the sump should also b[...]

77 MAINTENANCE Oil and Filter Change 1 1. Place towels under the oil filter . Using an oil filter wrench, turn the filter counterclockwise to remove it. 12. Clean the filter sealing area on the engine. 13. Lubricate the filte r o-ring. Check to make sure the o-ring is in good condition. 14. Install the new oil filter . After the filter contacts the[...]

78 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on pa ge 68. Maintain the oil level at the bottom of the fill plug hole. See page 121 for the part numbers of Polaris products. The fill plug is located on the left side of the A TV , under the rear fen[...]

79 MAINTENANCE T ransmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Check the oil level. 6. Add oil as needed. Do not overfill. 7. Reinstall the fill plug. T orque to specification. See page 78 for recom- mendations.[...]

80 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Place a drain pan under the gearcase. 6. Remove the drain plug. Use a 15 mm wrench. 7. Allow the oil to drain completely . 8. Clean and reinstall the d[...]

81 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginni ng on page 68. W e recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of compo- nents. See page 12 1 for the part number[...]

82 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Check the oil level. 6. Add the recommend ed oil as needed to bring the level to the bottom of the fill hole threads. 7. Rein[...]

83 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Place a drain pan under the gearcase. 6. Remove the drain plug. Use an 8mm Allen wr ench. 7. Allow the oil to drain complete[...]

84 MAINTENANCE Cooling System The engine coolant level is controll ed, or maintained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expa nding (hea ted) excess coolant is forced out of the [...]

85 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair . If the recove[...]

86 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. If the fluid leve l is low add DOT 4 bra ke fluid only . See page 121 for the part numbers of Po laris products. Under normal operation, the diaphr agm extends into the reservoir as flui[...]

87 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar . Main- tain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder . Do not over- fill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. V iew the fluid level through the indicator win- dow (eye) on [...]

88 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the hand lebar . The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommende d to keep the brake system in good operating condition. Check more ofte[...]

89 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. 1. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahead position. 3. T ie a length of string between two stands as shown in the illustration. [...]

90 MAINTENANCE Steering Assembly The steering assembly o f the A TV should be check ed p eriodically for loose nuts and bolts. If loose nu ts and bolts are found, see your Polaris dealer for service before operati ng the vehicl e. Side P anel Removal 1. Remove the seat. 2. Grasp the top of the side panel and pul l it outward to remove it. F ootwell[...]

91 MAINTENANCE Tires Refer to the specifications section begin ning on page 126 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. F ront Wheel Hub Tightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operations. All ser[...]

92 MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Loosen the wheel nuts slightly . 5. Place a suitable stand under the footrest frame to raise the whee l slightly off the ground. 6. Remove the wheel nut s. 7. Remove the wheel.[...]

93 MAINTENANCE Tires Wheel Installation 1. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts finger tight. 3. Lower the vehicle to th e ground. 4. T orque the wheel nuts to specification. Wheel Nut T orque Specifications Check the w[...]

94 MAINTENANCE Air Filter 1. Position the vehicle on a level surface. Place the transmission in gear . 2. Lock the parking brake. 3. Remove the seat. 4. Release the air box cover clips, and remove the air box cover . 5. Loosen the clamp and remove the filter . 6. Remove the fabric type pre-fil- ter from the main filter . W ash the pre-filter in soa[...]

95 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Measure the[...]

96 MAINTENANCE Lights When servicing a halog en lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlamp Replacement 1. T urn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly . 2. Remove[...]

97 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the housing before storing the vehicle. Make sure the hous- ing is completely dry before reinstalling the drain plug. 1. Place the transmission in gear . 2. Lock the parking brake. 3. S top the engine. 4. Remove the drain screw on th[...]

98 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications sect ion beg inn ing on pa ge 1 26 for the recom- mended spark plug t ype and gap for yo ur vehicle. T orque spark plugs to specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operation. Check the spark plug firing end condition after th[...]

99 MAINTENANCE Spark Plugs Spark Plug Condition Normal Spark Pl ug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be flaky and whi te. A white insulator tip[...]

100 MAINTENANCE V ehicle Immersion If it's impossible to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the vehicle out o f the water . 2. T urn the fuel valve off. 3. Check the air box. If water is present, dry the air box and replace the filter with a new filter . 4. Remove the spark plug. 5. Loosen [...]

101 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur ge accumulated carbon from the exhaus t pipe/muffler . 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Remove the arrestor clean-out plu g from the bottom of the muffl er . 5. Star t the engine. 6. Quickly [...]

102 MAINTENANCE PVT System WAR N I NG F ailure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failu re may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be ou[...]

103 MAINTENANCE PVT System PVT Drying There ma y be some ins tances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Move the vehicle out o f the water . 2. Remove the PVT drain p lug. Use a 17 mm wre nch, a flat sc rew- driver , or the spark plug wrenc h. 3. Allow the water to[...]

104 MAINTENANCE Battery Y our A TV may have either a sealed battery , which requires little mainte- nance, or a conventional battery . A sealed battery can be identified by its flat covers on the top of the battery . A conventional battery has six filler caps on the top of the battery . Always keep battery terminals and connections free of corrosio[...]

105 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parking brake. 3. Remove the sp lash shield behind the right front tire. 4. Remove the left side panel to access the battery hold- down bracket. Remove the screw at the bottom rear of the bracket and move the bracket aside. 5. Remove the battery cover . 6. On co[...]

106 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructio ns on page 108 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the batter y in [...]

107 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three month s or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e an d recharge as needed to maintain a full char ge. NOTE: Batter[...]

108 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electrolyt e du ring charging. See page 105. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.27[...]

109 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: When using an a utomatic charger , re fe r to the charger manufacturer' s instructions for recharging . When using a constant current charger , use the following guideli nes for recharging. Always verify battery con- dition before and 1-2 ho urs after the end of charging. State of[...]

110 MAINTENANCE Cleaning and Storage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing clot h, cleaning[...]

111 MAINTENANCE Cleaning and Storage W ashing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The wate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: • Wheel bearings • Radiator (if equipped) • T ransmissio[...]

112 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susce ptible to corrosion if no t properly clean[...]

113 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 1 10. Stabilize the F uel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel T reatment or Polaris Fuel S tabilizer . Follow the instructions on th e container for the rec o mm ended amount. NOTE: Carbo[...]

114 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change flu ids as recommended in th e Pe riodic Maintenance Chart beginn ing on page 68. • Demand drive unit (front gearcase) • T ransmission • Brake fluid (change every two years and any time the fluid loo ks dark or contaminated) Fog the Engine 1. T rea[...]

115 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate al l a reas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 68. Battery Storage See pages 107-108 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV with t[...]

116 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to preven t loss during transporting. 7. Always tie the frame of the A TV to th[...]

117 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Spring Adjustments The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Always ad just both sides equally . NOTE: Accessory springs are available throug h your Po laris dea[...]

118 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. 1. Loosen the four h andlebar bolts. 2. Adjust the handlebar to the desired height . NOTE: Be sure the handleb ars do not contact the gas tank or any other part of the m achine when turned fully to the left or right. 3. T orque the front two bolts to 10-12 ft. lbs. (14-[...]

119 ADJUSTMENTS Carburetor Y our Polaris A TV is calibrated at the fa ctory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) or higher . Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea ch[...]

120 ADJUSTMENTS Throttle Cable F reeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and sli de it far enough to ex pose the end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16&quo[...]

121 POL A RIS PRODUCTS Pa rt Number Description Engine Lubr icant 2870791 F ogging Oil (12 oz. Aerosol) 2876244 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (gal.) Gearcase / T ransmission L ubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium AGL S[...]

122 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range (if equipped). Starting out going up a steep incl ine Use low range (if equipped) or turn around using the K- turn (see page 60). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range (if[...]

123 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , F ails to Start Engine Backfires Possible Cause Solution Blown fuse Replace fuse Low battery voltage Recharge th e battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cause Solut[...]

124 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Possible Cause Solution [...]

125 TROUBLESHOOTING Engine Stops or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Overuse of choke Ins pect, clea n a nd/o r replace spark plugs Fouled [...]

126 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 400 HO 4X4 Maximum W eight Capacity 365 lbs. (166 kg) (includes weight of opera- tor , cargo and accessor ies) Dry W eight 5 98 lbs. (271 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 .2 qts. (2 l) T ransmission Oil 20.3 oz. (600 ml) Demand Dri[...]

127 SPECIFICA TIONS Jetting Chart Clutching Chart Sportsman 400 HO 4X4 Driving System T ype Automa tic PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (H/N/R) Drive Ratio, Front 3.6:1 Drive Ratio, Final 15.18:1 T i res/Pressure Front 24x8-12 / 5 psi (34.5 KPa) Rear 24x1 1-12 / 5 psi (34.5 KPa) Front Suspension MacPherson strut with 7&q[...]

128 W ARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s. This warranty cov[...]

129 WA RRANTY WARRANTY COVERAGE AND EX CLUSIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris limi ted warranty excludes any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This warranty also does not cover any A TV th[...]

130 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AN D FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY . Some states do not allow limi- tations on ho[...]

131 WA RRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries. Deal[...]

132 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, a ll warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have [...]

133 WA RRANTY U.S.A. EP A Emissions Limited Warranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limited warranty is in addition to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with the re[...]

134 MAINTENANCE L OG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMM ENTS[...]

135 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COM MENTS[...]