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in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. The safety alert warning indicates a potential hazard that may result in serious injury or death.

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

We've created a web site, just for YOU!! S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out
Check it out... www.polarisindustries.com/owner
1

WELCOME
Thank you for choosing Polaris, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles.
We believe Polaris sets the standard of excellence for all recreational vehicles manufactured in the world today. Many years of experience in engineering, design, and development have gone into making your Polaris vehicle the finest machine we've ever produced.
Follow the instructions and recommendations in this Owner's Manual for safe and enjoyable operation of your vehicle. Your Owner's Manual contains instructions for minor maintenance. Major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician.
Your Polaris dealer knows your vehicle best and is interested in your complete satisfaction. Return to your dealership for all of your service needs during, and after, the warranty period.
Polaris also takes great pride in our PAA (Parts Apparel and Accessories) which are available on our online store www.purepolaris.com. Have your accessories and clothing delivered right to your door!
Polaris and Polaris The Way Out are registered trademarks of Polaris Industries Inc.

Printed in the U.S.A.

WARNING
Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV Pro 500 is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating a Polaris ATV Pro 500.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis. If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.
NOTE: Illustrations used in this manual are for general representation only. Your model may differ.
3

TABLE OF CONTENTS
Vehicle Identification Numbers . . . . . . . . . . . . . . 6 Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . 7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Understanding Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 9 Key Safety Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Decals and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Features and Controls . . . . . . . . . . . . . . . . . . . . . 44
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Pre Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Vehicle Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . 63 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Carrying Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Noise Emission Control System . . . . . . . . . . . . 69 Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Pre Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Safe Riding Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4

TABLE OF CONTENTS
Maintenance and Lubrication . . . . . . . . . . . . . . . 82
Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . 82 Lubrication Recommendations . . . . . . . . . . . . . . . . . . . 88 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Filter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Water Immersion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 PVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . 135 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5

VEHICLE IDENTIFICATION NUMBERS
The frame vehicle identification number (VIN) (1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are essential to its recovery and identification. NOTE: Record your vehicle's ID numbers in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with an existing key. NOTE: If both keys are lost, see your dealer for ignition switch replacement.
2
1
Vehicle Model Number:
Frame VIN: Engine Serial Number:
Dealer Imprint:
6

VEHICLE SPECIFICATIONS

Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type

SPORTSMAN 700 1240 lbs. 4.75 U.S. Gallons 1500 lbs 150 lbs 85" 46" 47" 50.75 11" 740 lbs 71.5" 2 Quarts 3.2 Quarts EH68ALOE1 683 80 x 68 45 155 P-6(829) 4HB41-4 1.5 300 Watts @ 3000 rpm 9.78:1 Electric BST 34mm CDI 34 BTDC @ 3500 RPM RC7YC / 0.9 mm / .035 in Pressurized Wet Sump 4 Wheel Independent Shaft

VEHICLE SPECIFICATIONS

Shift Type
Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Front Brake Rear Brake Parking Brake Headlight (watts)
Taillights (watts) Brake Light (watts) Instrument Cluster

SPORTSMAN 700 Side Lever (High, Low, Neutral, Reverse, Park) 7.5/1 5.11/1 2.89/1 3.82/1 3.10/1 25 x 8 - 12 25 x 11 - 12 Hydraulic Disc Hydraulic Hydraulic lock, all wheel 1 - Single Beam on Handlebar (50) 2 - Single Beam on Grill (27) 8.26 26.9 LCD

Clutching and Jetting Charts

Altitude
Meters (Feet)

AMBIENT TEMPERATURE
0-1800 (0-6000)
1800-3700 (6000-12000)

Below 40° F Below 5° C
175
150

+40°Fand above +5°C to & above
162.5
140

Altitude

Meters (Feet)

0-1800 (0-6000)
1800-3700 (6000-12000)

Shift Weight

Drive Clutch Spring

Driven Clutch Spring

Helix*

20-56

Blue/Green White/Yellow

EBS

PN 5631315 PN 7041157 PN 7041635 PN 5132751

20-54

Blue/Green White/Yellow

EBS

PN 5631214 PN 7041157 PN 7041635 PN 5132751

EBS models require no helix / spring adjustment 8

SAFETY
Understanding Warnings
The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE:
A note will alert you to important information or instructions.
9

SAFETY
Key Safety Issues
Protect Your Sport Know all local, state/province riding laws; Respect your vehicle; Respect the environment; and You will gain the respect of others. We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals. All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc. Illustrations included in this manual are general representations of parts having a similar function. Your model may differ. AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.
10

SAFETY
Key Safety Issues
SERIOUS INJURY OR DEATH can result if you do not
follow these instructions:
S Read this manual and all labels carefully and follow the operating procedures described.
S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
S Never allow anyone under 16 years of age to operate this ATV. S Never permit a guest to operate this ATV unless the guest has read
this manual and all product labels, and has completed a certified training course. S Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. S Never operate an ATV on any public street, road or highway, even a dirt or gravel one. S Never operate an ATV without wearing an approved helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. S Never consume alcohol or drugs before or while operating this ATV. S Never operate at excessive speeds. Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience. S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. S Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation. S Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. S Never operate on excessively rough, slippery or loose terrain. S Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. S Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident.
11

SAFETY
Key Safety Issues
S Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed.
S Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.
S Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
S Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.
S Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
S Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (pg. 78), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes.
S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary apply them lightly several times to let friction dry out the pads.
12

SAFETY
Key Safety Issues
S Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.
S Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.
S Never modify an ATV through improper installation or use of accessories.
S Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764. Additional Important Information...
Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the ATV substantially increase the risk of bodily injury. Please be aware that these modifications may create a substantial safety hazard.
Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power.
We also advise you to strictly follow the recommended maintenance program outlined in this manual. This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage intervals.
NOTE:
The addition of certain accessories including (but not limited to) mowers, blades, tires, sprayers, or large racks may change the handling characteristics of the ATV.
Be certain any accessories added to this ATV have been approved by Polaris.
Familiarize yourself with their function and affect on the ATV.
13

SAFETY
Safety Decals and Locations
NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.
1
14

Safety Decals and Locations
WARNING
1

SAFETY

IF OWNER'S MANUAL IS MISSING, CONTACT

YOUR POLARIS DEALER FOR A REPLACEMENT.

E1997, 2000

7079083

SAFETY
Safety Decals and Locations
3 2
16

Safety Decals and Locations

WARNING

UNDER

SAFETY

Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.

NEVER operate this ATV if you are under

age 16.

7078253

3
WARNING

F Never operate this ATV on HILLS steeper than 25 degrees

25°

To prevent flipover on hilly terrain, when going up or down,

use throttle and brakes gradually.

F REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

F Use OVERRIDE for reverse speed limiter with caution. To prevent loss of control, never activate override button with open throttle.

F PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave shift in forward.

7079085

SAFETY
Safety Decals and Locations
4 5
6
18

Safety Decals and Locations
6

SAFETY
4

(on rear of seat)
5
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS.
Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible, and firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is best. For stability on rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack. Read Owner's Manual for more detailed loading information
7079084
19

SAFETY
Safety Decals and Locations

7 (Under Seat)

DOperation of this vehicle

ATTENTION DSpecific

without the air filter element

carburetor jetting

will severely damage the engine.

and adjustments are required

DClean pre-filter element often, more

depending on temperature and

frequent cleaning required

altitude. See your Owner's Manual.

in dusty conditions. Do not

operate vehicle without pre-filter.

Factory setting:

DOperation of this vehicle without

40_ to 80_ F. at 0-3000 feet

engine breather filter(s) can cause

(5_ to 27_ C. at 0-900 meters).

engine damage. Consult owner's

manual or dealer for details.

7079902

WARNING

Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle with

guard removed.

Do not modify engine or clutch. Doing so can cause part

failure, possible imbalance, and excessive engine RPM

which can result in serious injury or death.

NO STEP

7078689

Safety Decals and Locations
9

SAFETY
9

WARNING

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe

injury or death. Tow only from tow hooks or hitch.

Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs
7170021

WARNING
Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner's Manual.
7079604
AWD Models

ALL WHEEL DRIVE SWITCH
Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner's Manual.
7079780

MANUFACTURED BY: POLARIS IND INC.
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS.

PRINTED IN U.S.A.

7078472

TRAILER MAX WEIGHT: 1225 LBS. (556 KG) ON LEVEL GROUND 850 LBS. (368 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16KG) 7078261

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury.

1. Helmet

Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

Select an approved helmet which

meets or exceeds your state's

safety standards and bears either

the Department of Transportation

(DOT) label, the American

National Standards Institute label (ANSI z90.1), or the Snell

Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for

proper eye protection. A pair of

goggles or helmet face shield offer

the best protection for your eyes.

They should be kept clean and be

of shatterproof design (bearing the

markings z2.1 or VESC 8).

3. Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

4. Boots

The best footwear is a pair of strong over the calf type boots with heels, such as moto-cross boots.

5. Clothing

To protect your body, long sleeves and pants should always be worn. Riding pants with kneepads, a jersey and shoulder pads provide the best protection.

Operator Safety

SAFETY

WARNING

POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual.
For more information about the training course, contact an authorized ATV dealer or call Polaris at 1-800-342-3764.

WARNING
POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. Even though a child may be within the age group for which some ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris ATV.

SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
24

Operator Safety
WARNING

SAFETY

POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever possible. If you must ride on a paved surface, go slowly and do not make sudden turns or stops.
25

SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
26

Operator Safety
WARNING

SAFETY

POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly. You should also wear: eye protection (goggles or face shield); gloves; boots; long-sleeved shirt or jacket; and long pants.
27

SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
WARNING
POTENTIAL HAZARD Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions; and your experience.
28

Operator Safety
WARNING

SAFETY

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don't try to show off.
29

SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual.
WARNING
POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your ATV during operation.
30

Operator Safety
WARNING

SAFETY

POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
31

SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
32

Operator Safety
WARNING

SAFETY

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner's Manual. See page 72 . Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

WARNING

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills. Never operate ATV on hills steeper than 25_.

SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner's Manual. See pages 74 through 77. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
34

Operator Safety
WARNING

SAFETY

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner's Manual. See page 76. NOTE: A special technique is required when braking as you go downhill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.
35

SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. See page 77. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as described in the Owner's Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
36

Operator Safety
WARNING

SAFETY

POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards:
Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply rear brake as well, and then lock parking brake. Dismount on uphill side, or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner's Manual. See page 77.

SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures as described in the Owner's Manual.
WARNING
POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
38

Operator Safety

SAFETY

WARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which could lead to an accident.
HOW TO AVOID THE HAZARD
Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (pg 78), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes.
Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind you, resulting in severe injury.
HOW TO AVOID THE HAZARD
When you select reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident. HOW TO AVOID THE HAZARD Always use the correct size, type, and pressure as specified on page19.
WARNING
POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer.
40

Operator Safety
WARNING

SAFETY

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in the Owner's Manual for carrying cargo or pulling a trailer. See pages 66 through 68.

WARNING
POTENTIAL HAZARD Riding on frozen lakes and rivers. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator break through the ice. HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water before you are sure the ice is thick enough and sound enough to support the machine and its operator, as well as the force that is created by a moving vehicle.

Operator Safety

SAFETY

WARNING

After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage.

WARNING
Safe operation of this rider active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death.

CAUTION
Keep combustible materials away from exhaust system. Fire may result.

CONTROLS AND FEATURES
Controls
Engine Electrical Switches

WARNING
Activating the override button while throttle is open can cause loss of control resulting in severe injury or death.

1. Override Switch (Reverse Speed

Limiter) - This vehicle is equipped

with a reverse speed limiter

OFF RUN OFF

system. To obtain additional power

while backing up, depress the

override button. NOTE: The

override switch also allows

activation of AWD (All Wheel

Drive) in reverse, if the AWD switch is on. When not in reverse the

switch also acts as the "mode button" for the instrument cluster.

2. Main Switch - To start the engine, slide the stop switch to the

center "run" position and turn the main key switch clockwise past

the "on" position. Release the key when the engine starts.

3. Engine Stop Switch - The engine will not start or run when the

switch is in its "off" position. Its purpose is to provide the

operator with a quick means of engine shutdown in case of stuck

throttle or other emergency. NOTE: Both the main switch and the

emergency engine stop switch shut off all electrical power to the

entire vehicle including lights. To stop the engine, slide the stop

switch right or left to the "off" position.

CONTROLS AND FEATURES
Controls
Engine Throttle and Choke
WARNING
Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death. Always contact your dealer for service repairs whenever throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident. Always check the lever for free movement and return before starting the engine and occasionally during riding.

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is released.

This vehicle is equipped with

a Polaris Electronic Throttle

Control (ETC) which is

designed to reduce the risk of

a frozen or stuck throttle. In the event the throttle cable should stick in

an open position, the engine will stop and power to the rear wheels will

cease when the operator releases the throttle lever.

Choke

Refer to the engine starting procedure on page 64 for correct choke and throttle settings during starting.

CONTROLS AND FEATURES
Controls
Brakes The front and rear brakes are applied by squeezing the left side brake lever toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only. Always test brake lever travel and reservoir fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.
WARNING
Never operate the ATV with a spongy feeling brake lever. Operating the ATV with a spongy brake lever can result in loss of braking. Loss of braking could cause an accident.
46

Controls

CONTROLS AND FEATURES

WARNING
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

Front and Rear Brakes

The brake fluid in the master

cylinder, which is located on the

left handlebar, should be checked before each ride. The fluid level

can be seen through an indicator

window (1) on the top of the

master cylinder. This "eye" will

appear dark when the fluid level is

full. When fluid needs to be

added, the eye will be clear.

NOTE: When checking the fluid

level, the ATV must be on level

ground the the handlebars straight.

If the fluid level is low add DOT 3

(PN 2870990) only.

WARNING
Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of severe injury.

CONTROLS AND FEATURES
Controls
Parking Brake
WARNING
Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the parking brake is left on while the ATV is operated.

Setting the Parking Brake

1. Put the vehicle gear selector

into park.

2. Squeeze the left hand brake

lever two or three times and

hold it.

3. Push the park brake lock (2)

into the notches on the master

cylinder body. Release the

brake lever.

4. To release the parking brake

lock, squeeze the brake lever.

It will return to its released

position.

Important Safeguards
S The parking brake may relax when left on for a long period of time. This could cause an accident.
S Do not leave the vehicle on a hill depending on the parking brake for more than five minutes.
S Always put the gear selector in park and block the downhill side of the wheels if leaving the ATV on a hill or park the ATV in a side hill position.

Controls
Foot Brake

CONTROLS AND FEATURES

WARNING
Use caution when applying the foot brake. Do not aggressively apply the foot brake when going forward or the rear wheels may skid and slide sideways causing loss of control.

1
Your Polaris ATV has a foot brake (1) provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the main brake system, especially if the main system becomes inoperative. If the rear wheels slide, reduce brake pedal pressure to brake the rear wheels without skidding. Aggressively applying the rear brake when backing down a hill may cause rear tip over. Brake Fluid Level It will be necessary to check the brake fluid level for the foot brake. The reservoir is located under the RH rear cab. The fluid should be kept between the maximum and minimum marks.

CONTROLS AND FEATURES

Controls

Fuel System

The fuel tank filler cap (1)

is located directly behind

the handlebar. Refer to

vehicle specifications on

page 7 for tank capacity.

Use either leaded or

unleaded gasoline with a

minimum pump octane

number of 87 (R+ M/2)

octane.

The fuel valve is located on the left side panel and has three positions:

OFF: For vehicle storage and whenever transporting.

ON: For normal operation.

RES: For reserve supply in

the event of main supply exhaustion.

RES

NOTE: There is about a 7

to 10 mile (11.2 to 16 km)

range on reserve gas.

Always refill the gas tank

OFF

as soon as possible after

having used the reserve

supply.

Always return valve to "on" position after

refueling machine.

Fuel Filter

The Polaris ATV is equipped with an in-line fuel filter.

This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

Controls
Fuel Safety

CONTROLS AND FEATURES

WARNING
Gasoline is highly flammable and explosive under certain conditions.
S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped and outdoors or in a well
ventilated area. S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored. S Do not over fill the tank. Do not fill the tank neck. S If you get gasoline on your skin or clothing, immediately wash it
off with soap and water and change clothing. S Never start the engine or let it run in an enclosed area. Gaso-
line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. S Shut off fuel valve whenever the ATV is stored or parked.

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

CONTROLS AND FEATURES

Controls

Automatic Transmission Gear Selector

The transmission gear selector is located

on0 the right side of the vehicle directly above and forward of the engine and has

five positions: high, low, neutral; reverse,

and park. To shift into "High" or "Park", you

must first depress the foot brake to

activate the High/Park lock out mechanism.

When shifting out of "High" or "Park", it is

not necessary to depress the brake.

NOTE: To extend belt life, use low

forward gear in heavy pulling situations

and in situations where you are operating below 7 miles per hour for extended

periods of time.

CAUTION
To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Depress the foot brake if shifting into high or park. Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

Always place the transmission in park with the parking brake locked whenever the vehicle is left unattended.

GENERAL RANGE OPERATION GUIDELINES:

Low Range

Heavy pulling, basic operational speeds less than 7 MPH, riding through rough terrain (swamps, mountains, etc.), low ground speeds.

High Range

High ground speeds, speeds above 7 MPH.

CONTROLS AND FEATURES
Important Safeguards S Always back slowly avoiding excessive speed and do not use the
reverse speed override switch system unless additional power is required for vehicle movement. S Avoid turning at sharp angles in reverse. S Avoid backing on steep inclines.
Light Switches and Indicator Lights
WARNING
This ATV is not equipped with highway approved lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

Oil Pressure Switch
Some 2002 Sportsman 700 ATVs were produced without an oil pressure switch as standard equipment.
If your model has this switch, it will be located on the LH side of the engine next to the oil filler tube. It is not to be confused with the engine temperature switch that is located on the same side but higher up on the engine.
If the oil pressure switch is not installed on your engine, the oil pressure warning is not active and the diagnostic mode feature is not valid.

Engine Temperature Switch
Oil Pressure Switch

CONTROLS AND FEATURES

Features

Exclusive AWD System (All Wheel Drive)

Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) system which is activated by a switch (1) on the right handlebar. When the switch is "off" the ATV is in 2 wheel drive at all times. When the switch is "on" the ATV is in All Wheel Drive and the AWD indicator(2) will light.

1 2

When in AWD, the front wheels will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage.

NOTE: The override switch also allows activation of All Wheel Drive (AWD) in reverse, if All Wheel Drive switch is on.

There is no limit to the length of time the vehicle may remain in All Wheel Drive.

The All Wheel Drive switch may be turned on or off while the vehicle is moving. If the switch is turned off when the front hub is driving it will not release until the rear wheels regain traction. To protect the front drive system, the AWD will not engage if the engine is running higher than 3100 RPM. Once enabled, the AWD system will work at any RPM.

CAUTION
Do not switch on All Wheel Drive if the rear wheels are spinning. This may cause severe drive shaft and hub damage.

CONTROLS AND FEATURES
Features
Exclusive AWD System (All Wheel Drive) Engage the All Wheel Drive switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the All Wheel Drive switch on. NOTE: If the instrument cluster is not registering a proper gear indication, AWD can still be enabled by pressing the mode/override button. Disengaging Wheel Hubs When backing or while in All Wheel Drive and then going forward again, the AWD hub may remain engaged. If the hub remains engaged it can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward again. NOTE: If the hub remains engaged after following these instructions return the ATV to your dealer for service. Switches The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also switches the lights from Hi to Lo on models equipped with Hi-Lo beams. NOTE: The lights will not work unless the key is in the on position and shut off switch is in the "run" position.
55

CONTROLS AND FEATURES
Features
Instrument Cluster Your Sportsman 700 is equipped with an instrument cluster which senses vehicle speed from the right hand 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 ATV's speed at approximately 7 to 9 mph. Refer to page 44 for additional information.
3 2
1
1 Rider Information Center 2 Speedometer needle - in addition to depicting vehicle speed, this
needle will flash indicating a fault condition. 3 Speedometer
CAUTION
Do not wash the instrument cluster with a high pressure washer. Water under high pressure may enter the instrument cluster and cause damage to the electronic components. Wash the unit by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow gasoline to remain on the instrument cluster. 56

CONTROLS AND FEATURES

Features

Rider Information Center

The rider information center is located in the lower portion of the instrument cluster.

1 Gear Indicator As the shift lever

is moved, this

will indicate the

gear the machine

is in:

H = High Range

L = Low Range

N = Neutral

R = Reverse

P = Park

E or blank = Error

- Most of the time,

this error message

will indicate you

are inbetween

gears. It can,

however, also

indicate the

transmission

switch is broken.

2 High Engine Coolant Temperature 3 Low Oil Pressure 4 Hour Meter 5 Service Interval 6 Low Battery and over voltage

NOTE: All segments of the rider information center will light up for 2.5 seconds at start-up.

CONTROLS AND FEATURES
Features
Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button which is found on the LH handlebar is also the "mode button". NOTE: If using the mode button to program the rider information center, or to toggle through the options, the machine cannot be in reverse. Mode 1 - Odometer This will record the amount of miles the ATV travels. Mode 2 -Trip Meter To reset the trip meter, select the tripmeter mode. Press and hold the mode button (override button) until the total changes to "0" . NOTE: In the Rider Information Center, the trip meter is displayed with a decimal point, the odometer is displayed without a decimal point. Mode 3 - Hour Meter This mode logs the total hours the engine has been in operation.
58

CONTROLS AND FEATURES
Features
Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and their dealer with a convenient way to schedule routine maintenance. When your vehicle leaves the factory, this feature is turned "OFF". You must enable this feature if you intend to use it to track maintenance requirements. The service interval mode operates by service hours. To set the hours, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. At this point, each time the button is pressed, the setting will increase by one hour. Pressing and holding the button will allow the numbers to escalate much faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to "0". At this point you can re-attempt to set the number. Once the service interval mode is set, it will count down to "0" according to the hours your engine is running. When the counter times out at "0", the wrench icon will flash quickly for 5 seconds every time the vehicle is started as a reminder that the next periodic maintenance is due. If the service interval is enabled on your ATV and you wish to turn it off, toggle to the service interval mode. Press and hold the mode button for approximately 7 seconds until the word "OFF" appears in the Rider Information Center.
59

CONTROLS AND FEATURES
Features
Rider Information Center Diagnostic Mode
CAUTION
The diagnostic mode is for informational purposes only. Your dealer is fully equipped with the knowledge and special tools required to keep your machine running. Please return your ATV to your dealer for all major repairs.
To enter the diagnostics mode: 1. Turn the key switch off and wait 20 seconds. 2. Set the park brake and shift the transmission to neutral. 3. Hold the mode/reverse override button as you turn the key switch
on. The initial screen displayed looks similar to this illustration and is referring to the software version currently installed in your machine. This information is only briefly displayed. Use the mode/reverse override button to toggle through the diagnostic screens. The first screen indicates battery voltage.
60

CONTROLS AND FEATURES
Features
Rider Information Center
The second screen provides a full diagnostic indication of the entire oil pressure electrical circuit. Along with the letters PrSSr, there will be a box on the LH side. If the box is high, the pressure is normal. If the box is low, the pressure is low. Screen three is the tachometer for setting idle speed. If this needs adjustment, please contact your dealer. As long as you are in the diagnostic mode, the wrench icon will remain lit. To leave the diagnostic mode, either shift the machine out of neutral or turn the keyswitch off and on. NOTE: Any movement of the tires will also take the machine out of the diagnostic mode.
Auxiliary Power Outlet Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights and is located on the front headlight pod. Accessory outlets are available for all models. Contact your Polaris dealer for more information.
61

OPERATION
Pre Ride Inspection
WARNING
You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.
Use the following checklist to verify your machine is in proper working order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to their proper levels 3. All brakes - check operation, adjustment and fluid level (includes
foot brake) 4. Throttle - check for free operation and closing 5. Headlight/Taillight/Brakelight - check operation of all indicator
lights and switches 6. Engine stop switch - check for proper function 7. Wheels - check for tightness of wheel nuts and axle nuts; check
that axle nuts are secured by cotter pins 8. Air cleaner element - check for dirt; clean or replace 9. Steering - check for free operation noting any unusual looseness in
any area 10. Loose parts - visually inspect vehicle for any damaged components
or loose nuts/bolts or fasteners 11. Operators helmet, goggles and clothing 12. Engine coolant - check for proper level at the recovery bottle
62

OPERATION
Break-In Period
The break in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
CAUTION
Use only Polaris Premium 4 All Season synthetic oil, or API certified "SH" oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.
Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts.

1. Fill fuel tank with

either unleaded or

leaded fuel which has a minimum pump

SAFE

ADD 8 OZ

octane number of 87=

(R+ M)/2.

2. Check oil reservoir level indicated on dipstick. Add oil if

necessary.

3. Drive slowly at first. Select an area which is open and will give

you room to familiarize yourself with vehicle operation and

handling.

4. Vary the throttle positions. Do not operate at sustained idle or

sustained high speed.

5. Perform regular checks on fluid levels, controls and all important

areas on the vehicle as outlined earlier on the daily pre-ride

inspection checklist found on page 62.

6. Pull only light loads.

7. Break in oil and filter. Change at 20 hours or 200 miles.

OPERATION
Starting the Engine
Procedure for Starting a Cold Engine
WARNING
Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors.
CAUTION
You must allow your vehicle adequate warm up time before operating or engine damage could result.
1. Place the transmission in neutral or park and reset the parking brake.
2. Turn the fuel tank valve to ON. 3. Sit on the vehicle. 4. Pull the choke out all the way. 5. Turn the engine stop switch to
RUN. 6. Turn the ignition key past the
"ON" position to engage the starter.
NOTE: the choke is on "FULL" when the knob is pulled out all the way. The choke is "OFF" when the knob is pushed in. This is a variable choke and can be adjusted gradually, depending on how much choke is needed for starting. 7. Do not press the throttle while starting the engine. 8. Activate the starter for a maximum of five seconds, releasing the
key when the vehicle starts. If engine does not start, release the starter and wait five seconds; then activate the starter for another five seconds. Repeat this procedure until engine starts.
64

OPERATION
Starting the Engine
After the Engine Starts 1. If the engine slows or stops, use of the choke at half way in will
allow proper engine warm up. 2. Vary the engine RPM slightly with the throttle to aid in warm up
until the engine idles smoothly. Then push the choke all the way in. Cold Weather Operation Polaris offers an engine heater kit for cold operation. If you use your ATV all year round, it is important to check your oil level frequently. A rising oil level could indicate the accumulation of water in the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. The cold weather kit not only reduces moisture accumulation, but the heater will provide quicker warm-ups and easier starting. See your dealer for more information on cold weather operation and if the heater kit will enhance your cold weather operation.
65

OPERATION
Carrying Loads
Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Maximum trailer weight - 1500 (680 kg) on level ground only with a maximum vertical hitch weight of 150 lbs. (68.04 kg). NOTE: The rear rack capacity and tongue weight should not exceed 180 lbs. Maximum grade while trailer towing - 15°. Do not tow any trailer on a grade steeper than 15° (850 lbs on grades up to 15° ). Your machine is equipped with a front rack, take care when loading. Improper loading of the front rack can obstruct the headlight beam, reducing night visibility. Do not obstruct the headlight beam with cargo. Use of low forward gear is recommended in heavy pulling situations to extend belt life.
66

Carrying Loads

OPERATION

WARNING
Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load affects the vehicle's turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death.

2/3 of Load on Rear Rack

1/3 of Load on Front Rack

Important Safeguards To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below: S REDUCE SPEED AND ALLOW GREATER DISTANCE
FOR BRAKING WHEN CARRYING CARGO. S CARGO WEIGHT DISTRIBUTION should be 1/3 on the
front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on one rack only increases the possibility of vehicle tip over. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations which may require backing downhill. S ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.
67

OPERATION
Carrying Loads
S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.
S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads which cannot be centered, securely fasten load and operate with extra caution. Always attach the tow load to the hitch point designated for your ATV.
S EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.
S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.
S DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.
68

NOISE EMISSION CONTROL SYSTEM REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING: 1. Removal or alteration or the puncturing of the muffler or any engine
component which conducts removal of engine exhaust gases. 2. Removal or alteration or the puncturing of any part of the engine air
induction system. 3. Replacement of any vehicle parts with parts not in compliance with
federal regulations. 4. Lack of proper maintenance.
CAUTION
Remember, exhaust system components are very hot during and after use of ATV. Serious burns can result if hot components are touched.
S Do not touch exhaust system components. Serious burns can result.
S Be especially careful when traveling through tall grass. The potential for fire exists.
USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A.
69

RIDING
Pre Ride Inspection
WARNING
You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.
Use the following checklist to verify your machine is in proper working order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to their proper levels 3. All brakes - check operation, adjustment and fluid level (includes foot
brake) 4. Throttle - check for free operation and closing 5. Headlight/Taillight/Brakelight - check operation of all indicator
lights and switches 6. Engine stop switch - check for proper function 7. Wheels - check for tightness of wheel nuts and axle nuts; check that
axle nuts are secured by cotter pins 8. Air cleaner element - check for dirt; clean or replace 9. Steering - check for free operation noting any unusual looseness in
any area 10. Loose parts - visually inspect vehicle for any damaged components or
loose nuts/bolts or fasteners 11. Operators helmet, goggles and clothing 12. Engine coolant - check for proper level at the recovery bottle
70

Safe Riding Tips
Riding Position

RIDING

1. Sit upright with both feet on the footrests and both hands on the handlebars.
2. After starting the engine and allowing it to warm up, shift the transmission into gear.
3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly depress the throttle with your right thumb and begin driving.
Vehicle speed is controlled by the amount of throttle opening. 6. Drive slowly, practice maneuvering and using the throttle and brakes
on level surfaces.
71

RIDING
Safe Riding Tips
Making Turns
Practice making turns at slow speeds. To turn, steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. The same leaning technique should be used for turning in reverse.
WARNING
Avoid turning at sharp angles in reverse as tipover and severe injury may result.
72

Safe Riding Tips
Riding on Slippery Surfaces

RIDING

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid
and shifting your body weight forward. 4. Driving with All Wheel Drive (All Wheel Drive) engaged can assist in
controlling the vehicle in slippery areas. 5. Never apply brakes during a skid. Complete loss of ATV control can
result. 6. Do not operate on excessively slippery surfaces if possible to avoid. 7. Always reduce speed and use additional caution.
CAUTION
Severe damage to drive train may occur if the Demand Drive is engaged while the wheels are spinning.
WARNING
Failure to exercise care when operating the ATV on slippery surfaces can be dangerous.
Loss of tire traction and vehicle control can result in an accident, including an overturn.
73

RIDING
Safe Riding Tips
Traveling Uphill
25_ Maximum
WARNING
Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death. Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills (25_ maximum). 2. Keep both feet on the footrests. 3. Transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening. 5. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the ATV.
74

Safe Riding Tips
Sidehilling

RIDING

Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward the hill
while keeping your feet on the footrests. 3. Steer slightly into the hill to maintain vehicle directions. If vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!
WARNING
Improperly crossing hills or turning on hills can be dangerous. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death.
75

RIDING
Safe Riding Tips
Traveling Downhill
Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the foot brake and its use in the event loss of normal service brakes occurs.
WARNING
Do not travel at excessive speeds. It is dangerous and can cause loss of vehicle control and tipping, resulting in severe injury or death.
76

Safe Riding Tips
Turning Around on a Hill

RIDING

8'
Uphill
If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1. Stop and lock the parking brake while maintaining body weight
uphill. 2. Leave transmission in forward and shut off engine. 3. Dismount on left or uphill side of ATV. 4. Staying uphill of ATV, turn handlebars full left (while facing front
of ATV). 5. While holding service brake, release parking brake lock and slowly
allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward. 6. Lock the parking brake and remount ATV from the uphill side, maintaining body weight uphill. 7. Restart engine with transmission still in forward, release parking brake, and proceed slowly, controlling speed with the service brake, until ATV is on reasonably level ground.
WARNING
Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV could occur resulting in severe injury or death.
77

RIDING
Safe Riding Tips
Crossing Streams
Your Polaris ATV can operate through water up to maximum recommended depths reaching the footrests. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the
lever until braking action is normal. S Avoid operating the ATV through deep or fast flowing water. If
you cannot avoid water which exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, maintain a slow and steady forward motion. Do not make sudden turns or stops and do not make sudden throttle changes. NOTE: After running the vehicle in water, it is critical your machine is serviced as outlined in the maintenance chart beginning on page 82. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings. If your vehicle becomes immersed, and it is impossible to take it to a dealer before starting, follow the steps described on page 121. It is still important the vehicle be serviced by your dealer at the first opportunity.
78

Safe Riding Tips
Trail Obstacles

RIDING

Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches.
WARNING
Not all obstacles are visible. Travel with caution on trails. severe injury or death can result if your machine comes in contact with a hidden obstacle.
79

RIDING
Safe Riding Tips
Backing Up
1. Avoid backing up on steep inclines. 2. Always back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. 6. Never activate override button while throttle is open. Loss of
control may result. NOTE: Most Polaris ATVs are equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Only open the throttle enough to maintain a desired speed.
CAUTION
Opening the throttle more than required may cause excessive fuel to build in the exhaust, resulting in engine popping and/or engine damage.
80

Safe Riding Tips
Parking on an Incline

RIDING

Whenever the Vehicle is Parked 1. Turn the engine off. 2. Place the transmission in park. 3. Set the parking brake. 4. Avoid parking on an incline. If it is necessary to park on an
incline, always block the rear wheels on the down hill side as shown above. 5. Shut off fuel supply.
81

MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart on the following pages. Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer. Service and adjustments are critical. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
CAUTION
Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.
" More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components. L Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California -only emissions warranty.
82

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours or When Remarks

Miles

Brake System

Pre-ride Pre-ride Pre-ride inspection item

Foot Brake

Pre-ride Pre-ride Pre-ride inspection item

Tires

Pre-ride Pre-ride Inspect daily, pre-ride inspection item

Wheels

Pre-ride Pre-ride Pre-ride inspection item

Frame nuts, bolts, fasteners

Pre-ride Pre-ride Pre-ride inspection item

" Air Filter - Pre-Clean- Pre-ride Pre-ride Inspect-Clean L er

Coolant/Level Inspection

Pre-ride Pre-ride Replace engine coolant every two years

Fuel and oil tanks

Pre-ride Pre-ride Fill to proper levels

Throttle

Pre-ride Pre-ride Check operation

Lights

Pre-ride Pre-ride Check operation

Engine Stop Switch Pre-ride Pre-ride Check operation

Steering

Pre-ride Pre-ride Check for free operation

" Air Box Sediment Tube

Pre-ride Pre-ride Drain deposits whenever visible

Headlamp Inspection Pre-ride

Pre-ride

Check operation daily; apply Polaris dielectric grease to connector when replaced

Tail lamp inspection

Pre-ride

Check operation daily; apply Polaris dielectric grease to socket when replaced

" Air Filter - Main Ele- Weekly Weekly Inspect-Replace if neces-

L ment

sary

MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule

CAUTION
Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

" More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
L Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California -only emissions warranty.

Item

Hours or When Remarks

Miles

" Transmission Oil Level

20 hrs Monthly Inspect monthly; change annually

Battery

20 hrs Monthly Check Terminals/clean/ check fluid level

" Engine breather filter 20 hrs L (4-cycle)

Monthly Inspect-replace annually and as needed

J Brake pad wear

20 hrs Monthly Inspect periodically

" Front and Rear Gear- 100 hrs Monthly Check monthly and

case Oil (shaft drive)

change annually

" General Lubrication 50 hrs 3

Lubricate all fittings, pivots,

months cables, etc.

" Engine Oil - Level/ L Change (4-Cycle)

100 hrs / 6 1000 months miles

Check Level Daily; Break in Service at 1 month. Change oil more often in cold weather use.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours or When Remarks

Miles

" Oil Filter(4-Cycle) L

100 hrs / 6 1000 months miles

Replace with oil change

L Engine breather hose (4-cycle)

100 hrs 6

Inspect

months

Carburetor Float Bowl

50 hrs 6

Drain bowl periodically and

months prior to storage

J Throttle Cable/ETC Switch

50 hrs

6 months

Inspect-adjust, lubricate, replace if necessary; preride inspection item

L Choke (Enricher) Cable

50 hrs 6

Inspect, lubricate, replace

months if necessary

Coolant strength/

100 hrs

pressure test system

6 months

Inspect strength seasonally; pressure test system annually

J Drive belt

50 hrs 6

Inspect, replace if neces-

months sary

" Steering

50 hrs 6

Inspect daily, lubricate

months

" Front Suspension

50 hrs 6

Inspect-lubricate, tighten

months fasteners

" Rear Suspension

50 hrs 6

Inspect, tighten fasteners

months

L Spark Plug

100 hrs 12

Inspect-replace if neces-

months sary

" Rear Axle

50 hrs 6

Inspect bearings, Lube

months

MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule

CAUTION
Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

Item
J Ignition Timing L J Fuel System L
J Fuel Filter
Radiator
Cooling System hoses Spark arrestor
J Clutches (drive and driven)

Hours or When Miles

100 hrs 12 months

100 hours

12 months

100 hrs 100 hrs 100 hrs 100 hrs 100 hrs

12 months
12 months
12 months
12 months
12 months

Remarks
Inspect and adjust as needed Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years. Replace annually
Inspect/clean external surface Inspect
Clean out
Inspect, clean

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours or When Remarks

Miles

Engine Mounts

100 hrs 12

Inspect

months

J Valve Clearance L

100 hrs 12

Inspect/Adjust

months

J Brake fluid

200 hrs 24

Change every two years

months

J Front wheel bearings 300 hrs 36

Inspect, replace if neces-

months sary

L Idle Speed

As Re- As Re- Adjust quired quired

J Toe adjustment

As re- As re- Periodic inspection, adjust quired quired when parts are replaced

Headlight Aim

As re- As re- Adjust if necessary quired quired

MAINTENANCE AND LUBRICATION
Lubrication Recommendations

Item

Lube Rec

Method

Frequency*

(1)Engine Oil

Polaris Add to proper level on dipPremium stick. See page 96. 4 Synthetic 0W40

Check level daily.

(2) Brake Fluid

DOT 3 Only

Maintain level between fill lines. See page 47.

As required; change every two years or 200 hours

(3) Transmission Oil

Polaris Premium Synthetic gear case lube

See Page 98

Change annually or at 100 hours

(4) Front

Premium See Page 99

Gearcase Oil Hub Lube

Change annually or at 100 hours

(5) Rear Gearcase Oil

GL5 80-90 Weight Gear Lube

Change Annually or at 100 hours

(6) Front Prop Shaft U-joints

Grease+ Locate Fittings and Grease

Every 3 months or 50 hours

(7) Front Propshaft Yoke

Grease+

Locate fittings and grease Every 3

- 3 pumps maximum

months or 50

hours

MAINTENANCE AND LUBRICATION
Lubrication Recommendations
(4) Front Gear Case

Fill plug (5) Rear Gear Case

(3) Transmission (plug)

Fill plug (6) Front Prop Shaft (U-Joints)
(7) Propshaft Yoke

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(8) Front Drive Axle (U Joint) (AWD Models)

Grease+ Locate grease fitting and grease with grease gun.

Every 3 months or 50 hours

(9) Ball Joint

Locate fitting on back side of Every 3

Grease struts and grease with grease months or

gun.

50 hours

(10) Front A Arm Pivot Shaft

Locate fitting on pivot shaft Every 3

Grease and grease with grease gun. months or

50 hours

(11) Upper L

Locate fitting on steering post Every 3

steering Post Grease and grease with grease gun. months or

Bushing

50 hours

(12) Upper L

Locate fittings and grease

Control Arms Grease

Semiannually

(13) Lower L

Locate fittings and grease

Control Arms Grease

Semiannually

(14) Rear Wheel Hub Bearing Carrier

L Grease **

Locate fitting and grease

Semiannually

(15) Rear

Locate fitting and grease

Anti-Roll Bar Grease

Semiannually

L More often under severe use, such as wet or dusty conditions.

**Polaris Premium all Season Grease or grease conforming to NLGI

No. 2, such as

Conoco Superlube M or Mobilegrease Special.

+ Grease every 500 miles, or before long periods of storage or after pressure washing, or after submerging in water. Always use Polaris Premium U-Joint Lube for maximum service of these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.).

When suspension action becomes stiff or after washing.

NOTE: Hours are based on 10 mph average.

MAINTENANCE AND LUBRICATION
Lubrication Recommendations

(11) Steering Post Bushing

(8) Axle Cardan Front Drive

(10) Front A Arm Pivot Shaft

Upper

(13) Lower Control Arm
(12) Upper Control Arm

(13) Lower Control Arm
(15) Rear AntiRoll Bar

(14) Rear Wheel Hub Bearing Carrier

MAINTENANCE AND LUBRICATION

Periodic Maintenance Record Use the following chart to record periodic maintenance work:

Maintenance Interval
Performed
First 5 Hrs.
25 Hrs.
50 Hrs.
75 Hrs.
100 Hrs.

Servicing Servicing

Date

Dealer

or Person

Remarks

MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle(1), located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle.

The engine coolant level is

controlled or maintained by the

recovery system. The recovery

system components are the recovery

bottle, radiator filler neck, radiator

pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

To access the recovery bottle it is necessary to remove the left side panel as described on page 130.

MAINTENANCE AND LUBRICATION
Engine Cooling System
WARNING
Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.

Radiator Coolant Level Inspection

NOTE: This procedure is

only required if the cooling

system has been drained for

maintenance and/or repair.

However, if the recovery bottle has run dry, the level in the

radiator should be inspected

and coolant added if necessary.

To access the radiator pressure

cap:

Using the tool provided, remove the four screws securing front rack (1). Remove front cover (2) by placing your fingers under the front of the cover and pulling upward.

MAINTENANCE AND LUBRICATION
Engine Cooling System
NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should need replacement contact your dealer for the correct replacement part. To insure that the coolant maintains its ability to protect the engine, it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer's mixing recommendations for the freeze protection required in your area. Using a funnel, slowly add coolant as necessary through the radiator filler neck.
95

MAINTENANCE AND LUBRICATION
Lubrication
4-Cycle Premium 4 Synthetic Lubricant
CAUTION
Use only Polaris Premium 4 All Season synthetic oil or API certified "SH" oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.
Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° F to 120° F. Its exceptional frictional properties result in more efficient operation, more power output, lower fuel consumption, and easier starting in cold temperatures. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified "SH" oil is allowable. Oil may need to be changed more frequently if Polaris Premium 4 is not used. You will also need to follow the manufacturers recommendations for ambient temperature operation.
96

MAINTENANCE AND LUBRICATION
Lubrication
Oil and Filter Change 1. Place vehicle on a level surface. 2. Run engine two to three minutes until warm. Stop engine. 3. Clean area around drain plug. 4. Place a drain pan beneath engine crankcase and remove drain plug.
CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result. 5. Allow oil to drain completely. 6. Replace sealing washer on drain plug. NOTE: The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches. 7. Reinstall drain plug and torque to 14 ft. lbs. (19 Nm). 8. Place shop towels beneath oil filter. Using an oil filter wrench, turn filter counterclockwise to remove. 9. Using a clean dry cloth, clean filter sealing surface on crankcase. 10. Lubricate O-ring on new filter with a film of new engine oil. Check to make sure the O-ring is in good condition. 11. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn and additional 1/2 turn. 12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 13. Place gear selector in neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks. 15. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 16. Dispose of used filter and oil properly.
NOTE: Drain Plug Torque: 14 ft. lbs. (19 Nm); Oil Filter Torque: Turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn.
97

MAINTENANCE AND LUBRICATION

Lubrication
Transmission Lubrication
The transmission fill plug is located on the right side of the machine behind the propshaft shield or footwell.
The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. With the ATV on a level surface, remove fill plug (1) and check the lubricant level. Use the illustration and the chart below to determine the correct fluid level. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478).

Model Sportsman 700

Oil Level "A" Oil Fill Ounces (ml)

1 5/8

13.5 (400)

Transmission Oil Changing Procedure

1. Remove the

four screws

on the

footwell

and gently pull

outward for 1 access.

2. Remove fill plug.

3. Remove transmission drain plug (2)

located on the bottom left hand side

and drain the oil. Catch and discard

used oil properly.

4. Clean and reinstall the drain plug

torque to 14 ft. lbs. (1.93 kg-m).

5. Add the correct amount of Polaris

Premium Synthetic Gearcase

Lubricant

until oil reaches the bottom of the

filler hole.

6. Check for leaks.

7. Reinstall footwell and screws

removed in step 1.

MAINTENANCE AND LUBRICATION

Lubrication

Front Gearcase Lubrication
The front gearcase fill plug is located as shown.
The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually.
With the ATV on a level surface, remove fill plug and check the lubricant level. Lubricant should be kept 3/4" from the bottom of the fill plug thread. The correct gearcase lubricant to use is Premium Hub Lube.

Fill plug

Gearcase Oil Changing Procedure
1. Remove fill plug (1). 2. Remove gearcase drain plug located on the bottom right hand side
and drain the oil. 3. Clean and reinstall the drain plug and tighten securely (14 ft.
lbs/1.93 kgm). 4. Add 5 ounces (150 ml) of Polaris premium hub oil. 5. Reinstall filler plug. 6. Check for leaks.

MAINTENANCE AND LUBRICATION

Lubrication

Rear Gearcase Lubrication

With the ATV on a level

surface, remove the fill plug and

visually inspect the lubricant

level through the fill hole (1).

The lubricant level should be

maintained 1 5/8 in. from the

top of the fill plug hole. Use

GL5 80-90 weight gear lube.

Gearcase Oil Changing Procedure
1. Remove drain plug (2). Catch and discard used oil properly. 2. Clean and reinstall the drain plug with a new sealing washer and
tighten securely (14 ft. lbs./1.93 kgm). 3. Remove fill plug and add 5 ounces (150 ml of GL5 80-90 weight
gear lube. Inspect the oil level. The oil level should be maintained 1 5/8 in. from the top of the fill plug hole. 4. Reinstall the fill plug. Tighten securely (14 ft. lbs/1.93 kgm). 5. Check for leaks.

100

MAINTENANCE AND LUBRICATION

Lubrication

Oil System

The oil dipstick and fill tube are located on the left side of the vehicle To check the oil:

1. Set machine on a level

surface.

2. Start the engine and let

it idle for 20-30

seconds.

3. Stop the engine and lift the lever lock (A) on the dipstick. Remove the dipstick and wipe it clean.

4. Re-install the dipstick completely, remove it and read the oil level. NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of stick consistent.

SAFE

ADD 8 OZ

5. Remove dipstick and check to see that the oil level is between the full and add marks. Add oil as indicated by the level on the dipstick. Do not overfill.

6. When reinstalling the dipstick, make certain to seat the lever lock.

101

MAINTENANCE AND LUBRICATION

Filter Systems

Cleaning the Main Filter

NOTE: It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observe the following practices.
1. Never immerse the filter in water since dirt can be transferred to the clean air side of the filter.
2. If compressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside.

NOTE: Replace the air filter every 50 hours, and possibly more often in very dirty conditions.

Air Filter Service - 4 Cycle

1. Remove seat.

2. Release clips and remove

cover.

3. Loosen clamp and remove

filter

4. Remove fabric type

pre-filter (1) from main

filter (2). Wash pre-filter

in soapy water and dry it.

5. Reinstall pre-filter over

main filter. Replace main

filter as required.

6. Reinstall filter into air box

and tighten clamp. Do not

over tighten clamp or filter

damage may occur.

102

MAINTENANCE AND LUBRICATION
Filter Systems
CAUTION
Operation of your ATV without a breather filter can cause engine damage.

Breather Filter and Hose

4-Cycle Engines With Dry Sump*

1. Take the filter(1) out of the hoses.

2. Inspect filter for debris.

Blow through gently in

direction of arrow on

filter to check for

clogging. Replace as

needed.

3. Check hoses for cracks,

deterioration, abrasion, or leaks. Replace as

needed.

103

MAINTENANCE AND LUBRICATION
Adjustments
Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable.
WARNING
If you determine your machine needs the tie rod adjusted for toe alignment, contact your dealer for service. Steering is a vital part of your machine that, if adjusted wrong, could lead to severe injury or death.
Toe Alignment You can check the toe alignment of the vehicle using the following method. The recommended toe alignment is 1/8 to 1/4 (.3 to .6 cm) toe out. If you discover improper adjustment have your dealer correct it. 1. Set the handlebars in a
straight ahead position and hold them in this position.
104

MAINTENANCE AND LUBRICATION
Adjustments
Toe Alignment (cont.) 2. Place stands in front of the machine, perpendicular to the rear tires. 3. Tie an elastic string around the stands, making sure string just
touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine. 4. Measure from string to rim at front and rear of front rim. Rear rim measurement should be 1/16 - 1/8 (.2 to .3 cm) more than front rim measurement. 5. If this measurement needs to be adjusted, contact your dealer for service.
105

MAINTENANCE AND LUBRICATION
Adjustments
Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer.
Rear Spring Adjustment Cam
106

MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death.
Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1. To locate handlebar bolts,
it will be necessary to remove the upper headlight pod. 2. Loosen the four bolts. 3. Adjust handlebar to desired height. Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right. 4. Torque handlebar adjuster block bolts to 10 to 12 ft. lbs. NOTE: Tighten bolts so there is an equal gap at the front and rear of the handlebar block. Improper gap will result in improper fit of upper pod.
107

MAINTENANCE AND LUBRICATION
Adjustments
Front Brake
WARNING
Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.

The front brakes are hydraulic disc brakes which are activated by the brake lever being moved toward the handlebar. These brakes are self-adjusting and require no adjustment.

The following checks are recommended to keep the brake system in good operating condition. How often they need checking depends upon the type of driving that has been done.

S Keep fluid level in the master cylinder reservoirs as described on

page 47. Normal functioning of the diaphragm is to extend into

the reservoir as fluid level drops. If the fluid level is low and the

diaphragm is not extended, a leak is indicated and the diaphragm

should be replaced. Always fill the reservoir as indicated whenev-

er the cover is loosened or removed to insure proper diaphragm

operation. Use Polaris DOT 3 brake fluid.

S Check brake system for fluid

leaks.

S Check brake for excessive

travel or spongy feel.

S Check friction pads for wear,

damage and looseness.

S Check security and surface

condition of the disc.

S Pads should be changed when

friction material is worn to

3/64 (.1 cm) (A), or about

the thickness of a dime.

108

MAINTENANCE AND LUBRICATION
Adjustments
Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system. The rear brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear. S Pads should be changed when the friction material is worn to 3/64
(.1 cm) which is about the thickness of a dime. S Inspect the brake disc spline and pad wear surface for excessive
wear. Foot Brake Your ATV's foot brake is intended to be used as a backup for the main brake system. Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right floorboard. All Polaris ATVs have hydraulic brake systems. The hydraulic foot brake will not require adjustment. NOTE: Since this is a rear brake only, it will not be as effective as the all wheel system.
109

MAINTENANCE AND LUBRICATION

Adjustments

Carburetor/Engine Idle RPM Adjustment

If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows:

1. Warm up the engine by

running the vehicle

approximately five

minutes.

2. Place the transmission in

gear with the parking brake

applied.

3. Adjust the carburetor idle screw (A) in or out until the desired idle

RPM is reached. Turning the screw in (clockwise) will raise RPM.

Turning the screw out (counterclockwise) will lower RPM.

Throttle Cable Free Play Adjustment

Throttle cable free play is adjusted at the handlebar.
1. Slide the boots (B) off inline cable adjuster sleeve(C). Loosen adjuster locknut (D).
2. Turn adjuster until 1/16 to 1/8 freeplay is achieved at thumb lever. NOTE: While adjusting freeplay, it is important you flip the throttle lever back and forth.
3. Tighten locknut and slide boots over cable adjuster until they touch at the mid point of adjuster.

110

MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation.
Important Safeguards Maintain proper tire pressure according to the tire pressure decal. Improper tire inflation may affect ATV maneuverability. Do not use improper tires. The use of non-standard size or type tires may affect ATV handling. Make certain the wheel are installed properly. If wheels are improperly installed it could affect vehicle handling and tire wear. Wheel Removal Procedure 1. Stop the engine, place the transmission in park and lock the
parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame. 4. Remove the wheel nuts and remove the wheel.
111

MAINTENANCE AND LUBRICATION
Adjustments
Wheel Installation
1. With the transmission in park and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
2. Attach the wheel nuts and finger tighten them. 3. Lower the vehicle to the ground. 4. Securely tighten the wheel nuts according to the chart found below:
The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service.
Wheel Nut Installation
The wheel nuts on your ATV have been installed with thread locker as an extra measure to ensure retention. This feature is intended to last until the wheel nuts are removed. NOTE: Wheel nut removal will be more difficult when thread locker has been used.
You have been supplied with replacement thread locker which you must use whenever reinstalling wheel nuts. Place one drop on the lug before installing and tightening to 30 ft. lbs. NOTE: Always use Polaris thread locker (PN 2870963) or equivalent when replacing wheel nuts. Always check wheel nut tension before riding your ATV.
Wheel Nut Torque Specifications

Bolt Size Front 3/8 Rear 3/8

Specification 30 Ft. Lbs. 30 Ft. Lbs.

NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris Dealer.

112

MAINTENANCE AND LUBRICATION

Adjustments

Tire Inspection

When replacing a tire always

use original equipment size

and type.

Tire Tread Depth
Always replace tires when tread depth is worn to 1/8 (.3 cm) (1) or less.

113

MAINTENANCE AND LUBRICATION
Adjustments
Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power for each 1000 foot (304.8 m) increase in elevation. Although this power cannot be regained, changes to the carburetor and drive system can be made to allow efficient operation. These changes include: 1. Carburetor re-jetting to compensate for altitude and/or temperature
changes. 2. Transmission convertor modification to adjust for engine
horsepower loss during high altitude operation. Contact your dealer. 3. On 4-cycle models, pilot screw adjustments can be made to compensate for temperature changes and/or changes in altitude. NOTE: Contact your dealer for altitude adjustments. They have the training and special tools required to perform all necessary modifications for you. Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polaris dealer to find out about the accessories available for your machine.
114

MAINTENANCE AND LUBRICATION
Lights - Adjustment - Replacement
Headlight Lamp Replacement
WARNING
Keep your headlights and taillights clean. Poor lighting while riding can result in an accident causing severe injury or death.
CAUTION
Do not service while headlight is hot. Serious burns may result. Do not touch a halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot which will shorten the life of the lamp.
115

MAINTENANCE AND LUBRICATION
Lights - Adjustment - Replacement
Headlight Lamp Replacement

Position knob in slot and secure in locking tabs

Adjustment Knob Stop

Snap pins into tabs
Slip O-Ring over pin
Route indicator harness over handlebar

1. Remove the three screws securing the headlight pod. 2. Using a small flat blade screwdriver, push in on the lock tab
through the two small openings at the front of the headlight pod. 3. Lift the pod lightly while depressing the tabs. 4. Lift pod cover up. Disconnect instrument cluster harnesses from
instrument cluster. Unplug indicator light harness and remove pod cover. 5. Unplug headlamp from wiring harness. 6. Remove boot and locking collar from back of lamp housing. 7. Grasp base of lamp and lift it out. 8. Reverse previous steps to replace lamp and reassemble pod. Make sure tab on lamp locates properly in housing.

116

MAINTENANCE AND LUBRICATION
Lights - Adjustment - Replacement
High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod. 1. Place the vehicle on a level surface with the headlight
approximately 25' (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height. 3. Start the engine and turn the headlight switch to high beam. 4. Observe headlight aim. The most intense part of the headlight
beam should be aimed 2 (5.1 cm) below the mark placed on the wall in step 1. NOTE: Rider weight must be included on the seat. 5. Adjust beam to desired position by turning the adjustment knob.
117

MAINTENANCE AND LUBRICATION

Lights - Adjustment - Replacement

Headlight Housing Replacement

1. Lift the pod lightly while depressing the tabs.

2. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod.

3. Remove the three screws securing the headlight pod.

4. Lift pod cover up. Disconnect instrument cluster harnesses from instrument cluster. Unplug indicator light harness and remove pod cover.

O-Ring

5. Unplug headlamp from wiring harness.

6. Remove O-Ring from headlight pivot pins.

7. Pull headlight housing up to release from locking tabs.

8. Lift adjusting knob up to remove from locking tabs.
9. Carefully pull assembly up and out of pod.
10. Reverse steps to install new housing and reassemble pod.
11. Adjust headlight aim by turning adjusting knob.

5 1/8 (13 cm)
Distance from headlamp parting line to end of adjustment knob stop is 5 1/8 (13 cm).

118

MAINTENANCE AND LUBRICATION

Lights - Adjustment - Replacement

Taillight/Brakelight Lamp Replacement

If the taillight/brakelight does not

work the lamp may need to be

replaced.

1. Remove the taillight lens cover

mounting screws. Remove the

lense cover and gasket and set

aside for reassembly.

2. Remove lamp (A) and replace

it with recommended lamp.

3. Test the taillight/brakelight to

see that it's working.

4. Reinstall the gasket and lens

cover (B) removed in step 1.

119

MAINTENANCE AND LUBRICATION
Spark Plugs Refer to page 7 for the correct spark plug for your machine. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. 1. Normal The insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments. 2. Wet Fouled The insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes are excessive oil use, improper use of the choke, or incorrect carburetion adjustments. Spark Plug Removal and Replacement
WARNING
Never attempt to remove a spark plug while the engine is warm. The exhaust system or engine could burn you causing severe injury.
The spark plug is removed by using the special wrench provided in the tool pouch. Remove the spark plug cap and then the spark plug by rotating counterclockwise. Reverse the procedure for spark plug installation. Torque to 17 ft. lbs. Never deviate from the recommended spark plug as engine damage can occur.
120

MAINTENANCE AND LUBRICATION
Water Immersion

CAUTION
If your ATV becomes immersed, take it to your dealer before starting the engine. Major engine damage can result if the machine is not thoroughly inspected.

If it is impossible to take it to a dealer before starting, follow the steps

outlined below.

S Move the ATV to dry land or at the very least, to water below the foot
rests.

S Turn the fuel valve off.

S Remove the spark plugs.

S Loosen the carburetor drain screw (1).

S Turn the engine over several times with electric start.

S Dry the spark plugs and reinstall or replace with a new plugs.

S Tighten the carburetor drain screw.

S Turn the fuel valve on.

S Attempt to start the engine. If necessary, repeat the "drying" procedure.

S Take the machine to your dealer for service as soon as possible, whether you succeed in starting it or not.

If water has been ingested into the PVT

follow the procedure on page 125 to dry out the PVT.

121

MAINTENANCE AND LUBRICATION
Spark Arrestor
WARNING
When cleaning the spark arrestor, you must follow the safeguards listed below to avoid serious injury or death. S Do not perform this operation immediately after the engine has
been run because the exhaust system becomes very hot. S Because of the increased fire hazard, make sure that there
are no combustible materials in the area when purging the spark arrestor. S Wear eye protection. S Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor. S Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas. S Do not go under the machine while it is inclined. S Keep combustible materials away from exhaust system. Fire may result.
Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows: 1. Remove the clean out plug (1) located on the bottom of the muffler. 2. Place the transmission in neutral and start the engine. Purge
accumulated carbon from the system by momentarily revving the engine several times. 3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the clean out plug while revving the engine several more times.
122

MAINTENANCE AND LUBRICATION

Spark Arrestor (cont.)

4. If particles are still

suspected to be in the

muffler, back the

machine onto an

incline so the rear of

the machine is one foot

higher than the front. Set the parking brake

and block the wheels.

Make sure the machine

is in neutral and repeat steps 2 and 3.

5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot

higher than the rear. Set the parking brake and block the wheels.

Make sure the machine is in neutral and repeat steps 2 and 3.

6. Repeat steps 2 through 5 until no more particles are expelled when

the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the arrestor plug.

123

MAINTENANCE AND LUBRICATION
PVT System
WARNING
The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the following responsibilities to make sure this system remains safe: S Do not modify any component of the PVT system. Doing so
may reduce its strength so that a failure may occur at high speeds. This system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. S Routine maintenance is the responsibility of the owner. Always follow recommended maintenance procedures. See your dealer! S This PVT system is intended for use on Polaris products only. S The PVT housing must be securely in place during operation.
Failure to comply with this warning can result in severe injury or death.
Low Range Use May Reduce PVT Operating Temperatures The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of "pinch" applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt "pinch."
124

MAINTENANCE AND LUBRICATION
PVT System
On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH, due to the system's dependence on engine speed. For example, when operating at a ground speed of 3 MPH in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of 1200 - 1400 RPM. However, in high range at 3 MPH, the engine would be running at only 1500 RPM. Whenever operating this close to the engagement speed, the engine may be running at a speed which is too low to provide adequate "pinch" needed to prevent belt slip. This belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail. By switching to low range while operating at low ground speeds, the air temperature in the clutch cover is reduced by almost 160 degrees. Reducing the temperature inside the clutch cover extends the life of the PVT components (belt, cover, etc.). NOTE; Models without a low range should avoid heavy pulling and extended low-speed operation. PVT Drying There may be some instances when water is accidently ingested into the PVT system. If this happens, use the following instructions to dry it out before operating. First remove the drain plug and allow the water to drain. Replace the drain plug. Start the engine and shift the transmission into neutral. Apply varying throttle for 10 to 15 seconds. This will expel the moisture and air-dry the belt and clutches. Allow the engine RPM to settle to idle speed and shift the transmission to the lowest available range and test for belt slippage. If the belt slips, repeat the process. Take the vehicle to your dealer for service as soon as possible.
125

MAINTENANCE AND LUBRICATION
PVT System
When To Use Low Range vs. High Range The following lists provide a guideline for when to use low range rather than high. Low Range: S Basic operation at speeds less than 7 MPH S Heavy pulling S Riding through rough terrain (swamps, mountains, etc.) at low
ground speeds High Range: S Basic operation at speeds greater than 7 MPH S High ground speeds
126

MAINTENANCE AND LUBRICATION
Battery
WARNING
Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could result causing serious injury or death.

WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Replenishing the Battery Fluid
A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks.
To refill use only distilled water. Tap water contains minerals which are harmful to a battery.

Maintain between upper and lower level marks

127

MAINTENANCE AND LUBRICATION
Battery
Battery Removal 1. Remove the strap securing the battery. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. Lift the battery out of the ATV, being careful not to tip it sideways and
spill electrolyte.
CAUTION
If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV.
Battery Installation and Connections
WARNING
To avoid the possibility of explosion, always connect battery cables in the order specified. Red (positive) cable first; black (negative) cable last. An exploding battery can cause serious injury or death.
Battery terminals and connections should be kept free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean rags. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into the battery.
128

MAINTENANCE AND LUBRICATION
Battery
1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and
securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte, severe burns could result. 3. First connect and tighten the red (positive) cable. 4. Second connect and tighten the black (negative) cable. 5. Reinstall battery and battery strap. 6. Verify that cables are properly routed. NOTE: S When your ATV is placed in storage for three months or more, the battery should be removed, charged to proper level, and stored in a cool dry place. S Before reusing, take the battery to your dealer for testing and recharging. S Power plug leads may need to be bent down so that the battery cover may be installed. S When installing a new battery, make certain it is fully charged prior to it's initial use. Using a new battery that has not been fully charged can damage the battery resulting in a shorter life of the battery. It can also hinder vehicle performance.
129

MAINTENANCE AND LUBRICATION

Side Panel Removal

Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.

1. Remove seat. Grasp rear of side panel near

rear cab. With a quick

and firm motion, pull

the panel forward and

outward to disengage

the two rear tabs.

2. Place hand on top of

side panel behind the

fuel tank. With a quick

and firm motion, push

down on the side panel

to disengage the top

rear two tabs. Then

pull up on side panel to

disengage front upper

and lower tab.

3. To reinstall side panel,

align panel tabs with

slots on front cab.

Push panel upward and

forward until tabs lock.

Bend rear of side panel and insert the two tabs

into the rear cab.

130

MAINTENANCE AND LUBRICATION
Cleaning and Storage
Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels. Many expensive repair bills can result from using high pressure detergent systems. NOTE: If a high pressure car wash is used, grease all zerk fittings immediately after washing. Also run the vehicle to evaporate any water that might have entered the engine or exhaust system. The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your a Polaris dealer for free replacement. Waxing the ATV Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish.
CAUTION
Certain products, including insect repellants and chemicals, will damage plastic surfaces. Care must be taken when using these products near plastic surfaces.
131

MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips Cleaning - Outside...Make necessary repairs and then clean the ATV thoroughly with a mild soap and warm water solution to remove all dirt and grime. Don't use harsh detergents or high pressure washers. Some detergents deteriorate rubber parts - use dish soap type cleaners only. High pressure washers may force water past seals. Drain the recoil housing. Stabilize Fuel - Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Fill the fuel tank. Follow instructions on the container for recommended amount. Carbon clean will also reduce the possibility of bacterial growth in the fuel system. It's best to allow 15-20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor. Turn the fuel valve to "OFF" and drain the carburetor bowl completely. Oil And Filter Change - (4-Strokes) Warm the engine and change oil and filter. Air Filter / Air Box - Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube. Breather Filter- Inspect and clean or replace the breather filter. Inspect All Fluid Levels - Inspect the following fluid levels and change if necessary: rear grear case; front gear case ; transmission; brake fluid (change every two years or as required if fluid looks dark or contaminated). Check and Lubricate Cables / Grease - Inspect all cables and lubricate with Polaris Cable Lubricant. Follow lubrication guidelines in the Maintenance Section of the Service or Owner's Manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease.
132

MAINTENANCE AND LUBRICATION
Cleaning and Storage
* Fog The Engine - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole use a section of clear 1/4 hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Install the spark plug and pull the engine over slowly with the recoil starter. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.
CAUTION
Do not start the engine during the storage period. This will disturb the protective film created by fogging.
Battery Maintenance - Remove the battery and add distilled water as required to the proper level. Do not use tap water which may contain minerals that reduce battery life. Apply Polaris Di-Electric Grease to the terminal bolts and terminals. Charge the battery at 1.4 amps or less until specific gravity of each cell is 1.265 or greater. Store the battery in a cool, dry, place. Charge can be maintained easily by using Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge. Battery Tendert can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. The only thing you need to do is check the fluid level once a month. Engine Anti-Freeze - Test engine coolant strength and change if necessary. Coolant should be replaced every 2 years. Storage Area/Covers - Set tire pressure and safely support the ATV with the tires 1-2 off the ground. Be sure the storage area is well ventilated. Cover the machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
133

MAINTENANCE AND LUBRICATION
Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn off the engine and remove the key. It may be lost if not
removed. 2. Turn the fuel valve to off. 3. Be certain the fuel cap, oil cap, and seat are installed correctly. 4. Always tie the frame of the ATV to the transporting unit securely
using suitable straps or rope. 5. Always place the transmission in park and lock the parking brake. Tool Kit To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kits are: S Screwdriver S Open end wrench (8-10 mm) S Open end wrench (12-14 mm) S Box end wrench S Tire pressure gauge S Spark plug wrench and handle S Spanner wrench for adjusting rear shock spring preload S Torx driver for rack removal
134

TROUBLESHOOTING

Clutch Drive Belt & Cover Related Issues: Diagnosis

Possible Causes

Solutions/What to do

Loading the ATV into a pick- Shift transmission to low range during

up or tall trailer when in high loading of the ATV to prevent belt burn-

range.

ing.

Starting out going up a steep incline.

When starting out on an incline, use low range, or dismount the ATV after first applying the park brake and perform the "K" turn as described on page 77 of this manual.

Driving at low RPM or low ground speed (at approximately 3-7 MPH).

Drive at higher speed or use Low Range. The use of Low Range is highly recommended for cooler PVT operating temperatures and longer component life.

Insufficient warm-up of ATVs exposed to low ambient temperatures.

Warm engine at least 5 min., then with transmission in neutral, advance throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.

Slow and easy clutch engagement.

Fast, effective use of the throttle for efficient engagement.

Towing/Pushing at low RPM/low ground speed.

Use Low Range only.

Plowing snow, dirt, etc./util- Use Low Range only. ity use.

Stuck in mud or snow.

Shift the transmission to Low Range, carefully use fast, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

135

TROUBLESHOOTING

Clutch Drive Belt & Cover Related Issues: Diagnosis

Possible Causes

Solutions/What to do

Climbing over large objects from a stopped position.

Remove the drain plug at the lower rear portion of the clutch cover. Shift the transmission to Low Range, carefully use fast, brief, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Belt slippage from water or snow ingestion into the PVT system.

Shift the transmission to neutral. Using the throttle, vary the engine rpm from idle to full throttle. Repeat several times as required. During this procedure, the throttle should not be held at the full position for more than 5 seconds. Clutch compartment seals should be inspected for damage if repeated leaking occurs.

Clutch malfunction.

For inspection of clutch components, please contact your Polaris dealer.

Poor engine performance.

Fouled plugs, foreign material or old fuel in gas tank, fuel lines, or carburetor. Contact your dealer for further service information.

ENGINE OVERHEATS

Debris lodged in screens

Remove and clean the screen. Remove the screen by pulling on the top portion of the screen, then remove the lower portion.

Plugged Radiator

Use a garden hose to flush any debris from the radiator fins. NOTE: High pressure washers can deform the radiator fins and reduce cooling efficiency.

136

TROUBLESHOOTING
Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have.
ENGINE TURNS OVER BUT FAILS TO START

No Fuel
Fuel Valve Off
Clogged Fuel Valve or filter

Water in Fuel Drain System

Spark Plug
No Spark to Spark Plug
Boot not properly seated on plug.
Contact Your Dealer

137

TROUBLESHOOTING
ENGINE STOPS OR LOSES POWER

No Fuel
Turn Fuel Valve to "Res"
Fuel Vent Line Kinked or Plugged
Water in Fuel

Spark Plug Fouled
Air Filter Clogged
Reverse Speed Limiter
Malfunction
Electronic Throttle Control
Malfunction
Contact Your Dealer

Engine Overheated
Clean Radiator screen and Radiator Core
Clean Engine Exterior
Contact Your Dealer

Overuse of Choke

138

- NOTES -
139

WIRING DIAGRAM
140

WARRANTY
LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc. REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the "customer copy", please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.
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WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the ATV due to fire, explosions or any other cause beyond Polaris' control. This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.
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WARRANTY
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law. HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person at Polaris. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect. Engine Oil 1. Always use Polaris engine oil. 2. Never substitute or mix oil brands as serious engine damage and voiding of warranty can result.
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INDEX
Accessories . . . . . . . . . . . . . . . . . . 114 Adjustments . . . . . . . . . . . . . . 104-114 Age Restrictions . . . . . . . . . . . . . . . . 3 Air Filter . . . . . . . . . . . . . . . . . . . . 102 All Wheel Drive . . . . . . . . . . . . . 54-55 AntiFreeze . . . . . . . . . . . . . . . . . 133 Automatic Transmission . . . . . . . . . 52 Auxiliary Power Outlet . . . . . . . . . . 61 AWD . . . . . . . . . . . . . . . . . . . . . . 54-55 Backing Up . . . . . . . . . . . . . . . . . . . 80 Battery . . . . . . . . . . . . . . . . . . 127-129 Battery Fluid . . . . . . . . . . . . . . . . . 127 Battery Installation . . . . . . . . . . . . 128 Battery Maintenance . . . . . . . . . . . 133 Battery Removal . . . . . . . . . . . . . . 128 Brake Fluid . . . . . . . . . . . . . . . . . . . 49 Brake, Auxiliary . . . . . . . . . . . 49, 109 Brake, Front . . . . . . . . . . . . . . . . . 108 Brake, Rear . . . . . . . . . . . . . . . . . . 109 Brakes . . . . . . . . . . . . . . . . . . . . . 46-47 BreakIn Period . . . . . . . . . . . . . . . 63 Breather Filter . . . . . . . . . . . . . . . . 103 Camber and Caster . . . . . . . . . . . . 104 Carburetor Adjustment . . . . . . . . . 110 Carburetor Adjustments . . . . . . . . 114 Carrying Loads . . . . . . . . . . . . . . 66-68 Choke . . . . . . . . . . . . . . . . . . . . . . . 45 Cleaning . . . . . . . . . . . . . . . . . 131-132 Cleaning and Storage . . . . . . . . . . 133 Cleaning the Main Filter . . . . . . . . 102 Clutching and Jetting Charts . . . . . . . 8 Cold Weather Operation . . . . . . . . . 65 Controls . . . . . . . . . . . . . . . . . . . 44-52 CONTROLS AND FEATURES . 44-61 Coolant Capacity . . . . . . . . . . . . . . . 7 Coolant Level . . . . . . . . . . . . . . . . . 93 Coolant Level Inspection . . . . . . . . 94 Cooling System . . . . . . . . . . . . . 93-95 Crossing Streams . . . . . . . . . . . . . . 78 Diagnostic Mode . . . . . . . . . . . . . . . 60 Disengaging Wheel Hubs . . . . . . . . 55 Displacement . . . . . . . . . . . . . . . . . . 7 Drive Ratio . . . . . . . . . . . . . . . . . . . . 8 Dry Weight . . . . . . . . . . . . . . . . . . . . 7 Electrical Switches . . . . . . . . . . . . . 44 Engine Idle RPM Adjustment . . . . 110 Engine Oil Capacity . . . . . . . . . . . . . 7 Engine Stop Switch . . . . . . . . . . . . 44 Features . . . . . . . . . . . . . . . . . . . . 54-61 Filter Systems . . . . . . . . . . . . . 102-103 Fogging The Engine . . . . . . . . . . . 133 Front Gearcase Lubrication . . . . . . . 99
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Fuel Capacity . . . . . . . . . . . . . . . . . . 7 Fuel Filter . . . . . . . . . . . . . . . . . . . . 50 Fuel Safety . . . . . . . . . . . . . . . . . . . 51 Fuel Stabilizer . . . . . . . . . . . . . . . . 132 Fuel System . . . . . . . . . . . . . . . . . . 50 fuel valve . . . . . . . . . . . . . . . . . . . . 50 Gear Reduction . . . . . . . . . . . . . . . . . 8 Gear Selector . . . . . . . . . . . . . . . . . . 52 Gearcase Oil Change . . . . . . . . 99-100 Gross Vehicle Weight . . . . . . . . . . . . 7 Handlebar Adjustment . . . . . . . . . 107 Headlight . . . . . . . . . . . . . . . . . . . . . 8 Headlight Adjustment . . . . . . . . . . 117 Headlight Housing Replacement . . 118 Headlight Lamp Replacement . 115-116 High Range . . . . . . . . . . . . . . . . . . 126 Hour Meter . . . . . . . . . . . . . . . . . . . 58 Ignition System . . . . . . . . . . . . . . . . . 7 Ignition Timing . . . . . . . . . . . . . . . . . 7 Instrument Cluster . . . . . . . . . . . . . . 56 Key Safety Issues . . . . . . . . . . . . 10-13 Know Your Vehicle . . . . . . . . . . . . . . 3 Light Switches . . . . . . . . . . . . . . . . 53 Lights . . . . . . . . . . . . . . . . . . . 115-119 Low Range . . . . . . . . . . . . . . . . . . 126 Lubrication . . . . . . . . . . . . . . . . 96-101 Lubrication Recommendations . . 88-91 Lubrication System . . . . . . . . . . . . . . 7 Main Switch . . . . . . . . . . . . . . . . . . 44 MAINTENANCE
AND LUBRICATION . . . 82-134 Maintenance Record . . . . . . . . . . . . 92 Making Turns . . . . . . . . . . . . . . . . . 72 NOISE CONTROL SYSTEM . . . . 69 Odometer . . . . . . . . . . . . . . . . . . . . 58 Oil Change . . . . . . . . . . . . . . . . . . . 97 Oil Filter Change . . . . . . . . . . . . . . 97 Oil Pressure Switch . . . . . . . . . . . . . 53 Oil System . . . . . . . . . . . . . . . . . . 101 OPERATION . . . . . . . . . . . . . . . 62-68 Operator Safety . . . . . . . . . . . . . . 23-43 Override Switch . . . . . . . . . . . . . . . 44 Parking Brake . . . . . . . . . . . . . . . 8, 48 Parking on an Incline . . . . . . . . . . . 81 Periodic Maintenance Schedule . 82-87 Pre Operation Inspection . . . . . . . . . 70 Pre Ride Inspection . . . . . . . . . . . . . 62 Premium 4 Synthetic Lubricant . . . . 96 Programmable Service Interval . . . . 59 PVT System . . . . . . . . . . . . . . 124-126 Rear Gearcase Lubrication . . . . . . 100 Rear Spring Adjustment . . . . . . . . 106

Rider Information Center . . . . . . 57-61 RIDING . . . . . . . . . . . . . . . . . . . 70-81 Riding on Slippery Surfaces . . . . . . 73 Riding Position . . . . . . . . . . . . . . . . 71 Safe Riding Gear . . . . . . . . . . . . . . . 22 Safe Riding Tips . . . . . . . . . . . . . 71-81 SAFETY . . . . . . . . . . . . . . . . . . . . 9-16 Safety Decals and Locations . . . . 14-21 Safety Training . . . . . . . . . . . . . . . . . 3 Safety Decals . . . . . . . . . . . . . . . 15-43 Side Panel Removal . . . . . . . . . . . 130 Sidehilling . . . . . . . . . . . . . . . . . . . 75 Spark Arrestor . . . . . . . . . . 69, 122-123 Spark Plug . . . . . . . . . . . . . . . . . . . . 7 Spark Plugs . . . . . . . . . . . . . . . . . . 120 Starting a Cold Engine . . . . . . . . . . 64 Starting the Engine . . . . . . . . . . . 64-65 Steering Inspection . . . . . . . . . . . . 104 Storage . . . . . . . . . . . . . . . . . . 131-132 Storage Tips . . . . . . . . . . . . . . . . . 132 Switches . . . . . . . . . . . . . . . . . . . . . 55 TABLE OF CONTENTS . . . . . . . . 4-5 Taillight/Brakelight
Lamp Replacement . . . . . . . . 119 Throttle Cable
Free Play Adjustment . . . . . . 110 Throttle Lever . . . . . . . . . . . . . . . . . 45

INDEX
Tire Inspection . . . . . . . . . . . . . . . 113 Tire Size . . . . . . . . . . . . . . . . . . . . . . 8 Toe Alignment . . . . . . . . . . . . 104-105 Tool Kit . . . . . . . . . . . . . . . . . . . . . 134 Towing Capacity . . . . . . . . . . . . . . . 7 Trail Obstacles . . . . . . . . . . . . . . . . 79 Transmission Lubrication . . . . . . . . 98 Transmission Oil Change . . . . . . . . 98 Transporting . . . . . . . . . . . . . . . . . 134 Traveling Downhill . . . . . . . . . . . . . 76 Traveling Uphill . . . . . . . . . . . . . . . 74 Trip Meter . . . . . . . . . . . . . . . . . . . . 58 TROUBLESHOOTING . . . . . 135-138 Turning Around on a Hill . . . . . . . . 77 Turning Radius . . . . . . . . . . . . . . . . 7 Specifications . . . . . . . . . . . . . . . . . 7-8 Understanding Warnings . . . . . . . . . . 9 VEHICLE ID NUMBERS . . . . . . . . 6 Warning, Read Owner's Manual . . . . 3 WARRANTY . . . . . . . . . . . . . 141-143 Water Immersion . . . . . . . . . . . . . . 121 WELCOME . . . . . . . . . . . . . . . . . . . 2 Wheel Removal . . . . . . . . . . . . . . 111 Wheel Installation . . . . . . . . . . . . . 112 Wheel Nut Installation . . . . . . . . . 112 Wheel Nut Torque Specifications . 112 WIRING DIAGRAM . . . . . . . . . . 140

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Acrobat Distiller 4.05 for Windows