Instruction/ maintenance manual of the product 9919412 Polaris
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P art No. 9919412 Rev 04 PRINTED IN THE USA W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND W ARNINGS.
A car d containing impor tant A T V safet y infor mation should be at tached to t he owner ’s manual on the nex t page. If you cannot locate t his card, or if it has been r emoved, pleas e call 1-800-342-3764 f or assis tance.
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2 Copyri ght 2004 Pola ris Sal es Inc . Al l inf orma tion c ontai ned wi thi n this publi c at ion is bas ed on the l ate st produc t infor mat ion at t he tim e of publi cat ion.
3 WELCO ME Thank you for purcha sing a Polar is vehicle , and welcome to our world- wide fa mily of Polaris owners. W e proudly produc e an exc iting line of utility a nd recr ea tional pr oducts.
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5 TABLE OF CONTENTS WELCOME 3 .................................... VEHICLE IDENTIFICA TION NUMBERS 7 ........... SAFETY 8 ...................................... CONTROLS 33 .................................. FEA TURES 41 ..............................
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7 VEHICLE IDE NTIFICATIO N NUMBERS Recor d your A TV’ s identific ation numbers and ke y number in the spaces prov ided. R emov e the sp are key and s tore i t in a safe pl ace. Y our key can be duplicated only by mating a P olar is key bla nk with one of your existing ke ys, so if both keys ar e lost, t he ignition sw itch mus t be rep laced.
8 SAFE TY Safety D ecals and Locations W arning decal s have been placed on the A TV for your protecti on. Read and fo llo w the i nstru ctio ns of t he decal s on t he A TV carefull y . If any of the decals depi cted in this m anual differ from the decals on your A TV , al ways read and fol low the i nstru ctio ns of t he decal s on the A TV .
9 SAFE TY Safety D ecals and Locations IMPRO PER TIRE PRESSUR E OR O VERLO ADING can cause loss of contr ol resulting in SEVER E INJUR Y OR D EA TH. TIR E PRESSUR E IN PSI (KPa ): FRON T 5 (34,5) REAR 5 (34,5) M AXIMUM W EIGHT CAP ACITY (Gross Vehicle Wei ght) INCLUDING MACHIN E, DRIVER AND CA RG O IS 1200 LBS.
10 SAFE TY Safety D ecals and Locations S DO NOT TOW F ROM RACK OR BUM PER. V ehic le damage or tipov er may r esult c ausing s evere injur y or death. T ow only f rom tow hooks or hit ch. S Max R ack Loads : Front 100 lbs . (45 k g) Rear 200 lbs . (91 k g) 7172749 S DO NOT TOW F ROM RACK OR BUM PER.
11 SAFE TY Safety D ecals and Locations ALL WHEEL DRIVE SWITCH Do not push s w itc h to engage AW D if t he rear wheels are spinning. This may cause severe drive shaf t and c lutch damage. See your Owner ’s Manual. 7079780 7172564 7170509 TRAILER MAX WEIGHT : 1500 LBS.
12 SAFE TY Safe R iding Gear Always wea r clothing suite d to the t ype of riding. A TV riding requir es specia l prote ctive clothing for c omfort and to reduce the cha nce of injury . 1. Helmet Y our helmet is the most important pie ce of protec tive gear for sa fe riding.
13 SAFE TY Operator S afety W ARNING Failur e to follow t he warnings cont ained in this m anual can result in serious injury or deat h. A Polaris A T V is not a toy and can be hazardous to operat e. This vehicle handles diff erently t han other v ehicles, s uch as motorcycles and cars.
14 SAFE TY Operator S afety The following two pa ges iden tify signal wor ds and symbols that appe ar in this manual. Y our safe ty is involved whe n t hese words and symbols are u sed. Become f amiliar with their mea nings befor e reading the manua l.
15 SAFE TY Operator S afety W ARNING Serious injury or deat h can result if y ou do not follow t hese instr uctions and pr ocedures, which are out lined in furt her detail within your owner ’ s m anual. S Read this ma nual and all labels c ar efully , and follow the ope ra ting proce dures de scribed.
16 SAFE TY Operator S afety S Always have th e A TV i nspect ed by an auth orized P olari s dealer if it’ s been invol ved in an accident. S Neve r oper ate on hills too steep for the A TV or for your abilitie s. Pra ctic e on smalle r hills befor e attempting lar ger hills.
17 SAFE TY Operator S afety S W et br akes ma y have r educed stopping a bility . T e st the brake s after lea ving wate r . If nec essa ry , apply them lightly sever al times to allow frict ion to d ry out th e pads. S Always chec k for obsta cles or people be hind the A TV bef ore oper at- ing i n reverse.
18 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Oper ating this A TV wit hout proper inst ruct ion. WHA T CAN HAPPEN The r isk of an ac cident is gr eatly incr eased if t he operator does not know how t o operate t he A TV pr operly in different sit uations and on different ty pes of ter rain.
19 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Carry ing a passenger on an AT V. WHA T CAN HAPPEN Carry ing a passenger great ly reduces the operat or ’s ability to balance and contr ol the A TV , which could cause an ac cident and injury t o the operat or and/or passenger.
20 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Oper ating this A TV on public str eets, r oads or highways. WHA T CAN HAPPEN The A T V could collide with anot her vehicle. HOW T O A VOID THE HAZARD Never oper ate the A T V on any public str eet, r oad or highway , including dirt and gravel r oads.
21 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Oper ating the A T V aft er consuming alcohol or dr ugs. WHA T CAN HAPPEN Consumpt ion of alcohol and/ or drugs could ser iously affect operat or judgment . Reaction t ime may be slower and operat or balance and percept ion could be affect ed.
22 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Att empting wheelies , jumps and other s tunts . WHA T CAN HAPPEN Att empti ng stunt s increases the chanc e of an accident , including an over turn. HOW T O A VOID THE HAZA RD Never att empt wheelies, jumps, or other s tunts.
23 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Removing hands f rom the handlebars or f eet from t he footr ests during operat ion. WHA T CAN HAPPEN Removing ev en one hand or foot c an reduce abilit y to cont rol the vehicle or c ould cause loss of balance and eject ion from the A T V .
24 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Failu re to use extra caution when oper ating on excess ively rough, slippery or loos e terrain. WHA T CAN HAPPEN Operatin g on exce ssivel y rough, s lippery or loose ter rain could cause los s of tr action or loss of cont rol, which could res ult in an accident or overt urn.
25 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Oper ating on excess ively st eep hills. WHA T CAN HAPPEN The v ehicle may over turn. HOW T O A VOID THE HAZARD Never operat e on hills t oo steep for t he A T V or for your abilit ies. Never oper ate the A T V on hills st eeper than 25 _ .
26 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD T raveling downhill improper ly . WHA T CAN HAPPEN Im properly desc ending a hill could cause los s of cont rol or overt urn. HOW T O A VOID THE HAZA RD Always f ollow proper procedur es for tr aveling down hills as des cribed in the owner ’ s manual.
27 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Im properly cros sing hills and turning on hills . WHA T CAN HAPPEN Im properly cr ossing or turning as hills could c ause loss of cont rol or overt urn.
28 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Stalling, rolling bac kwards or improper ly dismounting while climbing a hill. WHA T CAN HAPPEN The v ehicle could overt urn. HOW T O A VOID THE HAZA RD Maint ain steady speed when climbing a hill.
29 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Im properly operat ing over obstacles . WHA T CAN HAPPEN Oper ating over obst acles c ould cause loss of cont rol or overt urn. HOW T O A VOID THE HAZARD Befor e operating in a new ar ea, check for obs tacles.
30 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Oper ating the A T V through deep or fast -flowing wat er . WHA T CAN HAPPEN T ires may f loat, caus ing loss of trac tion and loss of cont rol, which could lead t o an accident or overt urn. HOW T O A VOID THE HAZARD Avoid operating t he A TV t hrough deep or fas t-f lowing water .
31 SAFE TY Operator S afety W ARNING POTENTIAL HA ZARD Oper ating the A T V with impr oper modific ations. WHA T CAN HAPPEN Im proper inst allation of ac cessories or modif ication of the A TV may c ause changes in handling which could lead t o an accident .
32 SAFE TY Operator S afety W ARNING Leaving the k eys in the ignit ion can lead to unaut horized use of the vehic le resulting in s erious injury or death.
33 CONTROLS Engine E lectrical S witches W ARNING Act ivating t he override s witch while t he throt tle is open can c ause loss of cont rol, res ulting in sever e injury or deat h.
34 CONTROLS W ARNING Oper ating an A TV wit h stic king or improper ly operating t hrott le contr ols could cause an ac cident and lead t o severe injur y or death. Never s tart or operat e an A T V with a s ticking or improper ly operat ing thrott le.
35 CONTROLS Light Sw itches The light switch is loca ted on the le ft handlebar . It’ s used to turn the lights on and of f and to switch the lights from HI to L O. NOT E: The lights won’t work unles s the key is in the ON posit ion and the shut -off swit ch is in t he RUN position.
36 CONTROLS Master Cylinder The brake f l uid in the master cylinde r (1) , which is loca ted on the left handle bar , should be check ed before each ride. T he flui d level can be seen thr ough an indicator window (2) on the top of the master cylinde r .
37 CONTROLS Park in g Brake W ARNING Oper ating the A T V while the park ing brake is engaged could result in an accident and serious injur y or death. Always c heck to be sure t he parking brak e is disengaged befor e operating. Setting the P arking Br ake 1.
38 CONTROLS Auxiliary Brake W ARNING Aggres sively applying t he auxiliary br ake when backing down a hill may c ause rear t ipover , which could res ult in serious injury or death. Use caut ion when applying the auxiliar y brake. Do not aggress ively apply the aux iliary brak e when going forward.
39 CONTROLS Choke The choke assists in starting a co ld engine. Refer to the engine sta rting proce dure on page 50 for cor rect choke and throttle settings during starting. Fuel V alve The fu el valv e (1) is locat ed on t he left si de panel. It has two positions: OFF : F or veh icle s torage and when transpor ting.
40 CONTROLS Automatic T r ansmission Gear Selector The transmission gea r sele ctor (1) is locate d on the right side of the vehicle . Shift patterns va ry , depending on your model.
41 FEATURES All Wheel D rive (A WD) S ystem Po laris 4-wheel d rive A TVs are equipped w ith a unique , Po laris -exclus ive, Al l Wheel Drive (A W D) syste m, which is activa ted by a switch ( 1) on the r ight handleba r . When the switch is of f, the A TV is in 2 wheel drive at all times.
42 FEATURES In stru men t Clus ter Y our A TV is e quipped w ith an instrume nt cluste r that senses ve hicle speed from the r ight front whe el. The instrument c l uster measur es distanc e in mile s or kilome ters as we ll as hour s of ope ra tion.
43 FEATURES In stru men t Clus ter Ride r Infor ma tion Center The r ider inf ormation ce nter is locate d in the instrume nt cluster . All segmen ts will light up for 2.
44 FEATURES In stru men t Clus ter Ride r Infor ma tion Center The r ider inf orma tion ce nter h as 4 standa rd modes: Mode 1 - Odometer Mode 2 - T ripmeter Mode 3 - T otal Service Hour s Mode 4 - T ac hometer The reve rse override button on the left handleba r is also the mode button .
45 FEATURES In stru men t Clus ter Ride r Infor ma tion Center Diagnos tic Mode The diagnostic mode is for infor mationa l purposes only . Please retur n your A TV to your dealer for a ll major r epa irs. As long as the gauge is in the diagnostic mode, the wrench icon will re main lit.
46 FEATURES In stru men t Clus ter Ride r Infor ma tion Center Diagnos tic Mode Screen 5: P r ogramma ble service inte rva l The purpose of the progr ammable se rvice interva l is to provide the consumer a nd dealer with a conve nient reminder for r outine maintena nce.
47 OPERATION Fuel Safety W ARNING Gasoline is highly f lammable and explosiv e under cert ain conditions . S Always ex ercise ext reme c aution whenever handling gas oline. S Always r efuel with t he engine stopped, and outdoor s or in a well ventilat ed area.
48 OPERATION Br eak-In Period The bre ak-in period f or your ne w Polar is A T V is define d as the first ten hours of opera tion, or the time it takes to use the first two full tanks of gasoline. No single ac tion on your part is as importa nt as fo llowing the proce dures for a proper bre ak-in.
49 OPERATION Pr e-Ride Inspection W ARNING If a proper ins pection is not done befor e each use, s evere injury or death c ould result. A lways inspect the v ehicle before eac h use to ensur e it’s in proper operat ing condition.
50 OPERATION Star ting the Engi ne Sta rti ng a Col d Engi ne W ARNING Engine exhaust cont ains poisonous car bon monoxide and can cause loss of cons ciousness r esulting in sev ere injury or death. Never r un an engine in an enclosed area. 1. Place the tra nsmission in P ARK and lock the pa rking brake.
51 OPERATION Star ting the Engi ne Sta rti ng a W arm E ngine W ar m engines do not normally require the use of the c hoke. Using the choke ca n ca use the spark plug to become we t fouled. 1. Position the vehicle on a leve l surfac e with the t ra nsmission in PA R K .
52 OPERATION Driving Safely Hauling Cargo Y our A TV ha s bee n designed to c arr y or tow a cer tain a mount of load. Always re ad a nd understa nd the load distribution wa rning labe ls on the vehi cle, an d never exceed t he weigh t capac ities outline d in the speci ficati ons s ectio n of the own er ’ s manual and on t he safety d ecals.
53 OPERATION Driving Safely Hauling Cargo W ARNING Hauling cargo im properly can alt er vehicle handling and m ay cause loss of c ontrol or br ake instabilit y and result in serious injury or deat h. Alway s follow these prec autions when hauling cargo: S REDUCE SPEED AND ALLOW GREA TER DI ST ANCES FOR BRAKING WHEN H AULING C ARGO.
54 OPERATION Driving Safely Driving Pr ocedures 1. Sit upright with both feet on the f ootrests a nd both hands on the handleba rs. 2. Start the e ngine a nd allow it to warm up, then shift the tran smission into gea r . 3. Check your surr oundings and determine your pa th of tra vel.
55 OPERATION Driving Safely Making T urns Y our A TV is e quipped with a solid rear axle, whi ch driv es bot h rear whe els e qually a t all times. This means that the wheel on the outside of the turn must travel a greate r dis tance t han th e ins ide wheel when turning and the inside tire must slip trac tion slightly .
56 OPERATION Driving Safely Driving on Slippery S u r faces Whe never riding on slippery surfaces s uch as wet trai ls or loose grave l, or during freezing weather, foll ow thes e precaut ion s: 1. Slow down when enteri ng sl ippery areas . 2. Engage A WD bef ore whe els be gin to lose trac tion.
57 OPERATION Driving Safely Driving Uphill Whe neve r traveling uphill, follow these pr ecauti ons: 1. Always trave l straight uphill. 2. A void steep hills (25 _ ma ximum). 3. Keep both f eet on the footre sts. 4. T ransfe r your weight forwa rd. 5. P roceed at a st eady rate of s peed and th ro ttle opening.
58 OPERATION Driving Safely Sidehilling W ARNING Im properly cr ossing hills or t urning on hills can r esult in los s of contr ol or vehicle over turn, result ing in severe injur y or death. Avoid cross ing the side of a hill when possible. Follow proper procedur es as outlined in t he owner ’s manual.
59 OPERATION Driving Safely Driving Downhill Whe neve r desce nding a hill, follow these pr ecaut ions : 1. P roceed di rectl y downh ill. 2. T ransf er your weight to the rea r of the vehicle. 3. Slow down. 4. Apply the brakes slightly t oa i di ns l o w i n g .
60 OPERATION Driving Safely T urning A round on a Hi ll W ARNING Im proper hill climbing pr ocedures could c ause loss of contr ol or overt urn and result in serious injury or deat h.
61 OPERATION Driving Safely Dr iving Through W ater Y our A TV can oper ate through wate r with a maximum rec ommended depth e qual to the bottom of the footrests (1). Follow these proce dures when opera ting through wate r: 1. Deter mine wate r depths and current before crossing.
62 OPERATION Driving Safely Driving Over Obstacles Be alert ! Loo k ahead and learn t o read the t errain you ’re traveli ng on. Be con stant ly al ert for hazards s uch as lo gs, ro cks and l ow hangi ng branch es. W ARNING Sever e injury or deat h can result if your vehicle com es in contac t with a hidden obst acle.
63 OPERATION Driving Safely Driving in Rever se Fo llow t hese precaut ion s when operat ing in r everse: 1. Always avoid back ing downhill. 2. Back slowly . 3. Wh en in reverse, apply the brake s lightly for stopping. 4. A void t urning a t sharp an gles i n reverse.
64 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on an inc line if possible . If it’ s unavoida ble, follow th ese precaut ion s: 1. T urn the engine of f. 2. Place the tra nsmission in P ARK. 3. Set the parking brake. 4. Always block the r ear wheels on the downhill side a s shown in the illustration.
65 EMISSION CO NTR OL SYST EMS Noise E mission Contr ol System Do not modify the engine, intake o r exhaust components, as doing so may af fec t complianc e with state a nd local noise leve l require ments. Cr ankcase Emission C ontrol S ystem This engine is equipped with a closed c rankc ase system.
66 MAINTENANCE AND LUBRICATION Accessor ies Auxiliar y power outlets provide 12V power for oper ating accesso ries such as ha nd held spot lights. See your Polaris dea l e r . Per iodic Maintenance Chart Care ful periodic ma intena nce will help kee p your vehicle in the safe st, most relia ble c ondition.
67 MAINTENANCE AND LUBRICATION Per iodic Maintenance Chart Perfo rm all servi ces at whichev er m aint enance int erval is reached fi rst. Item Maintenance I nterval (whic hever c omes fir st) Remarks.
68 MAINTENANCE AND LUBRICATION Per iodic Maintenance Chart Item Maintenance I nterval (whic hever c omes fir st) Remarks Hours Calendar Miles (Km) " Gener al lubric ation 50 H 3M 500 ( 800) Lubric ate all fittings , pivots , cables , etc .
69 MAINTENANCE AND LUBRICATION Per iodic Maintenance Chart Item Maintenance I nterval (whic hever c omes fir st) Remarks Hours Calendar Miles (Km) J E Spark plug 100 H 12 M 1000 (1600) I nspec t; repl.
70 MAINTENANCE AND LUBRICATION Per iodic Maintenance Recor d Use t he foll owing chart t o record period ic mai nten ance. Maintenance In terval Perfo rmed Se rv icing Date Ser vicing Dealer or Pe rs .
71 MAINTENANCE AND LUBRICATION Lubri cation Guide Chec k and lubric ate all compone nts at the interva ls outlined in the Periodic Mainte nanc e Chart beginning on page 66. Items not listed in the char t should be lubrica ted at the Gene ra l Lubrication inter val.
72 MAINTENANCE AND LUBRICATION Pr emium 4 Syntheti c Lubricant Polaris Pre mium 4 All Season synthetic engine oil ha s bee n specia lly for mulated for u se in Polaris 4-cyc le engines. It’ s a fully synthetic , high perf ormance , multi-viscosity oil de signed to provide the u ltimate in l ubricat ion p erformance and p rotecti on.
1 SAFE ADD 8 O Z 3 4 AD D 8 OZ. NOR MA L FULL 4 5 2 73 MAINTENANCE AND LUBRICATION Oil Check The 400/500 oil dipstick and fill tube (1) are loc ated on the left side of the A TV . The 600/700 dipstick/oil fill (2) is l oc ated on the engine a nd is accessi ble on the l eft si de of t he A TV .
74 MAINTENANCE AND LUBRICATION Oil and Filter Change Change the oil and filte r at the interv als outlined in the Periodic Maintena nce Chart beginning on page 66. Oil Change (400/500) 1. Position the vehicle on a level surf ace. Cl ean th e are a around the drain plug a t the bottom of the oil tank a nd the bottom of the engine.
75 MAINTENANCE AND LUBRICATION Oil Change (400/500) 7. Plac e shop towe ls bene ath the oil filte r . Using an oil filte r wre nch, turn the filter ( 1) counter clockwise and re move. 8. Lubric ate the gaske t on the new filter with a film of new engine oil.
76 MAINTENANCE AND LUBRICATION Oil Change (400/500) Oil Pump Pr iming This priming proce dure must be perform ed whenev er the oi l ho se conne ction be twee n the oil tank and pump inlet ha s been disconnec t ed .
77 MAINTENANCE AND LUBRICATION Oil Change (600/700) 1. P lace t he vehi cle on a level su rface. 2. Run the engine f or two to thre e minutes until war m . Stop the engine. 3. Clean the ar ea ar ound the drain plug. 4. Place a dra in pan beneath engine c rankc ase and remove the dra in plug.
78 MAINTENANCE AND LUBRICATION T r ansmission Oil (400/500) Always ch eck a nd change the tra nsmission oil at the interva l s outlined in the Periodic Maintena nce Chart beginning on page 66. W e rec ommend the use of Polaris Premium AGL Synthetic G ea rc ase Lubrica nt.
79 MAINTENANCE AND LUBRICATION Front Gear case Oil Always check an d change t he front gearcase o il at th e interv als outlined in the Periodic Mainte nanc e Chart beg inning on page 66. Mainta in the oil level even with the bottom of the fill hole threads (1) .
80 MAINTENANCE AND LUBRICATION T r ansmission Oil (600/700) Always che ck and c hange the tran smission oil at the inter vals outlined in the P erio dic Mai nten ance Ch art beginning on page 66. Maintain the tran smission oil leve l at the bottom of the fill plug hole (1).
2 1 3 81 MAINTENANCE AND LUBRICATION Rear Gearcase Oil (600/700) The rear g earcase fil l pl ug (1) i s lo cated on the rear o f the gearcase. Al ways check an d chang e the rear g earcase oi l at the inter vals outline d in the Peri odi c Maint enance C hart beginning on page 66.
82 MAINTENANCE AND LUBRICATION Engine Cooling S ystem Radiator Coolant Level T o ensure that the coola nt maintains its ability to protect the engine , we recomm end th at the sy stem be com plet ely drai ned every two y ears and a fresh m ixt ure of ant ifreeze and water add ed.
83 MAINTENANCE AND LUBRICATION Engine Cooling S ystem Coolant Level The r ecove ry bottle (1) is loca t e d on the left sid e of th e machi ne. T o acces s th e rec overy bottle, remove the left side pane l as outlined on pa ge 87. Mainta in the coola nt l e vel be twee n the minimum and maximum mar ks on the bottle (whe n the fluid is cool).
84 MAINTENANCE AND LUBRICATION Br akes The front and re ar bra kes are hydr aulic disc bra kes, ac tivated by moving the single brake leve r toward the handle bar . These bra kes are self- adjusting. The fo llowi ng check s are recom mended t o keep the b rake syst em i n good opera ting condition.
85 MAINTENANCE AND LUBRICATION Br akes 2. C heck t he brake s yst em for fl uid leaks . 3. C heck t he brakes for ex cessi ve travel or spongy fee l. 4. C heck th e frictio n pads for wear , damage a nd looseness. 5. C heck th e securit y and surface condition of the disc.
86 MAINTENANCE AND LUBRICATION Steer ing Assembly The stee ring assembly of the A TV should be chec ked pe riodica lly for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris deale r for ser vice bef ore oper ating t he vehic l e.
87 MAINTENANCE AND LUBRICATION Side P anel Rem oval 1. Remove the seat. 2. Gras p th e rear of th e side p anel n ear the rear cab . With a fi rm motion, pull the panel outwar d to disengage the side pane l from the grommet. 3. Pull the panel downwar d and rear ward to r emove it f rom the A TV .
88 MAINTENANCE AND LUBRICATION W ARNING Oper ating your A T V with worn t ires, improperly inflat ed tires, non-st andard tires or im properly inst alled tires will affect v ehicle handling and could cause an ac cident res ulting in ser ious injury or death.
89 MAINTENANCE AND LUBRICATION Wheel Installation 1. Place the tra nsmission in P ARK and lock the pa rking brake. W ARNING Im properly inst alled wheels can adver sely affect tir e wear and vehicle handling, which can res ult in serious injury or death.
90 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service 1. R emov e the s eat, releas e the air box cover c lips, and remove the a ir box cover . 2. Loosen the c lamp and remove the filte r . 3. Remove the fabr i c type pre- filter (1) fr om t he ma in filter ( 2).
91 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a halogen lamp, don’ t t ouc h the lamp with ba re finger s. Oil from your skin le ave s a r esidue , causing a hot spot that will shorten the life of the la mp. W ARNING Poor light ing while driving can r esult in sev ere injury or deat h.
92 MAINTENANCE AND LUBRICATION Lights High Beam Adjus tment The h eadli ght b eam can b e adjus ted slightly upward or downwar d. Use the following proce dure to make the adjustment. 1. Position the vehicle on a level surf ac e with the headlight approxima tely 25 ft.
93 MAINTENANCE AND LUBRICATION Lights Headlight Housin g Replacem ent 1. Remove the two screws on the lower front corner s of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rea r of the pod. 3. Lift the pod cover and disconne ct the speedome ter harne sses from th e speedo meter .
1 1 2 2 1 94 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Rem o val / Installation 1. T urn the back of the hea dlight harne ss (1) counter clockwise and pull the harness asse mbly away from the h eadli ght asse mbly . 2. Remove the he adla mp and install the new hea dlamp.
95 MAINTENANCE AND LUBRICATION Spar k Plugs Always use the spark plugs rec ommended for your A TV . Refer to the specif ications se ction beginning on page 1 18 for the rec ommended spark plug type and ga p. CAUTION Using non-r ecommended spar k plugs can res ult in serious engine damage.
96 MAINTENANCE AND LUBRICATION V e hic le Imme rsio n CAUTION If your vehic le becomes im mersed, major engine damage c an result if t he machine is not thor oughly inspect ed.
97 MAINTENANCE AND LUBRICATION Spar k Arr estor W ARNING Failur e to heed the f ollowing warnings while ser vicing the s park arres tor could result in serious injur y or death. Do no t perform service on the sp ark arrestor wh ile the system is hot. Exhaust syst em tem peratures ca n reach 1000 ° F .
98 MAINTENANCE AND LUBRICATION PV T System The basic oper ation of the Polaris PVT system is depe ndent on engine speed and veh icle t orque req uirem ents. As en gine s peed in creases, the forc e exer t ed on the movable drive she ave by the flyweights also incre ases.
99 MAINTENANCE AND LUBRICATION PV T System W ARNING Failure t o comply wit h the inst ruct ions in this warning can result in sever e injury or death. Do not modify any component of th e PVT syst em. Doing so may reduce it s str ength so t hat a f ailure may occ ur at a high speed.
100 MAINTENANCE AND LUBRICATION Batter y Y our A TV ma y have eithe r a se ale d batte ry , whic h re quires little maintena nce, or a conve ntional battery . A sea led batte ry can be identifie d by its flat cover s on the top of the ba ttery . A conve ntional batte ry has six f iller cap s on the top of the batte ry .
101 MAINTENANCE AND LUBRICATION Batter y Batt ery Removal 1. Disconnec t the hold- down strap holding the battery in position, and remove ba ttery cover . 2. On conventional batte ries, remove the batte ry vent tube. 3. Di sconn ect th e black (n egati ve) batt ery cable fi rst.
102 MAINTENANCE AND LUBRICATION Batter y Batter y Storage When t he vehi cle i s pl aced in s torag e for th ree mont hs o r more, th e batter y should be removed, store d out of the sun in a c ool, dry plac e and teste d m onthly . Befor e re using, take the b atter y to your dealer f or testing and r echar ging.
103 MAINTENANCE AND LUBRICATION Batter y Batter y Char ging (Sealed Battery) For a ref resh char ge, follow all instructions ca refully . 1. Chec k the batter y voltage with a voltmete r or multimeter . A fully cha r ged battery will r egiste r 12.8 V or higher .
104 MAINTENANCE AND LUBRICATION Accessor ies Auxiliar y power outlets provide 12V power for oper ating accesso ries such as ha nd held spot lights. Acce ssory outlets a re a vailable for all mod els. P olari s als o has a wi de range o f addit ion al accesso ries ava ilable for your A TV .
105 MAINTENANCE AND LUBRICATION Cleaning and S torage Sto rag e Tips CAUTION Star ting the engine dur ing the st orage period will dist urb the prot ective f ilm creat ed by fogging and dam age could occur . Nev er star t t he engine during the st orage period.
106 MAINTENANCE AND LUBRICATION Cleaning and S torage Sto rag e Tips Fog the Engi ne 1. Remove the spa rk plug and add 2-3 ta blespoons of Pre mium 4 Sy nthet ic 0W4 0 engi ne oi l. T o access the pl ug ho le, u se a sect ion o f clear 1 /4” ho se and a s mal l plas ti c squeeze b o ttle f illed w ith the pre- measur ed amount of oil.
107 MAINTENANCE AND LUBRICATION Cleaning and S torage Sto rag e Tips Batte ry Main tenanc e (Conventi onal) Remove the battery a nd add distille d water to the prope r leve l. Do not use tap water , w hich m ay contai n min erals th at reduce bat tery li fe.
108 MAINTENANCE AND LUBRICATION Chr ome Wheel C are (if equi pped) Pro per maint enance will p rotect ch rome wheels from co rrosio n, preserv e wheel l ife and en sure a “li ke new” app earance for man y years. 1. W ash ch rome r ims freque ntly .
109 ADJUSTMENTS Cam ber and Caster The cambe r and caster a re non-a djustable. Rear S pring The rea r shock absor ber spring is adjuste d by rota ting the ad juster ( 1) eit her clo ckwis e or counter clockwise to incre ase or decrease s prin g ten sion .
11 0 ADJUSTMENTS Car buretor /Idle RP M Y our Polaris A TV is ca librated at the fa ctory for optimal per for manc e at altitude s ranging f rom ze ro to 6, 000 fe et (1800 m) and tempe ratures of +40 degr ees F .
111 ADJUSTMENTS Throttl e Cable Freepl ay Throttle c able fre epla y i s adjuste d at the handleba r . 1. Slide the boots (1) off the inline ca ble adjuster slee ve (2). Loosen the adjuster loc knut (3). 2. T urn the adjuster until 1/16 ″ to 1/8 ″ freeplay is ach ieved at t he th umb l ever .
11 2 NOTES.
11 3 POLARIS PRODUCTS Part No. Descri pti on Engine Lubr icant 2870791 Fogging Oi l (12 oz. Aerosol ) 2871281 Premi um 4 Syntheti c 0W- 40 (4-Cycl e) Engine Oi l ( qt.) 2871844 Premi um 4 Syntheti c 0W- 40 (4-Cycl e) Engine Oi l ( gal.) Gearcase / T ransmi ssion Lubri cants 2873602 Premi um AGL Synthet ic Gear case Lube (qt.
11 4 TROUBLE SHOOTIN G Drive Belt and Cover Pr o blems Po ssibl e Cause Solution Dri ving the A TV ont o a pick up or tall trailer in high r ange. Shif t tr ansm is si on to l ow ra nge dur ing loa ding of t he A TV to pre vent be lt bur ning. Sta rti ng out going up a steep inclin e.
11 5 TROUBLE SHOOTIN G Contact your Polaris dea l e r for ser vice if you’re una ble to identify solutions using the following c harts. Engine Doesn’t T urn Over Possi ble Cause Solut ion Tripp ed circu it break er Reset th e b reaker Lo w battery v oltag e Rec har ge ba tte ry to 12.
11 6 TROUBLE SHOOTIN G Engine Backfires Possi ble Cause Solut ion W ea k spa rk fr om spa rk plugs Inspect, clean and /o r replace spark p lu gs Inco rrect spark p lug g ap or heat rang e Set ga p to .
11 7 TROUBLE SHOOTIN G Engi ne Stops or Loses Pow er Possi ble Cause Solut ion Out of fuel Ref u e l Kinke d or plugged fue l vent li ne In spect an d rep lace W ater presen t in fu el Repl a ce w it .
11 8 SPECIFICA TIONS SPORT SMAN 400 Gro ss V eh icle W eigh t 1200 lbs ./544 kg T owi ng Capac ity 1225 lbs ./556 kg Hit ch T ongue Capa cit y 120 lbs ./ 54 kg (Rea r r ac k wei ght and t ongue weig ht no t to exceed 18 0 lbs./8 1.6 k g) Fro nt R ack/S torag e Bo x C apacity 90 lbs .
11 9 SPECIFICA TIONS SPORT SMAN 400 Shif t T ype Side Le ver (H/ L/N/R/ P) Gear R edu ction - L ow 23.91/ 1 Gea r Reduc ti on - Reve rs e 16.30/ 1 Gear R edu ction - F orw ard 10.
120 SPECIFICA TIONS SPORT SMAN 500 Gro ss V eh icle W eigh t 1200 lbs ./544 kg T ow ing R ating 1225 lbs ./ 556 kg Un brak ed Trailer T o win g Cap acity* 1786 lbs ./810 kg Hit ch T ongue Capa cit y 120 lbs ./ 54 kg (Rea r r ac k wei ght and t ongue weig ht no t to exceed 18 0 lbs.
121 SPECIFICA TIONS SPORT SMAN 500 Shif t T ype Side Le ver (H/ L/N/R/ P) Gear R edu ction - L ow 23.91/ 1 Gea r Reduc ti on - Reve rs e 16.30/ 1 Gear R edu ction - F orw ard 10.
122 SPECIFICA TIONS SPORT SMAN 600 Gro ss V eh icle W eigh t 1240 lbs ./563 kg Fu el Cap acity 4.25 ga l. /16 l T owi ng Capac ity 1500 lbs ./681 kg Hit ch T ongue Capa cit y 150 lbs ./ 68.1 kg (Re ar ra ck c apa ci ty a nd tongue weig ht no t to exceed 20 0 lbs.
123 SPECIFICA TIONS SPORT SMAN 600 Shif t T ype Side Le ver (H/ L/N/R/ P) Gear R edu ction - L ow 7.49/ 1 Gea r Reduc ti on - Reve rs e 5.1 1/1 Ge ar Re ducti on - High 3.
124 SPECIFICA TIONS SPORT SMAN 700 Gro ss V eh icle W eigh t 1240 lbs ./563 kg Fu el Cap acity 4.25 ga l. /16 l T ow ing R ating 1500 lbs ./ 681 kg Un brak ed Trailer T o win g Cap acity* 1914 lbs . (868 kg) Fro nt R ack C apacity 100 lbs ./45. 4 kg Rear R ack C apacity 200 l bs.
125 SPECIFICA TIONS SPORT SMAN 700 Shif t T ype Side Le ver (H/ L/N/R/ P) Gear R edu ction - L ow 7.49/ 1 Gea r Reduc ti on - Reve rs e 5.1 1/1 Ge ar Re ducti on - High 2.
126 WARRANTY LIM ITED W ARRANTY Polaris Sale s Inc ., 2100 Highway 55, Medina, MN 55340, give s a SIX MONTH LIMITED W ARRANTY on all components of the Polaris All T errain V ehicl e (A TV) agains t defects in m ateri al or work mansh ip. Polaris also give s a one year limite d warr anty on the final drive c hain for fa ilure due to defe cts.
127 WARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIM IT A T IONS OF W ARRANTIES AND REM EDIES The Polar is limited warr anty exc ludes a ny failure s t ha t are not cau sed by a def ec t in mater ial or workma nship. This warranty doe s not cover accid ental d amage, no rmal wear an d tear , ab use or i mpro per handl ing .
128 WARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W AR RANTIES OF MERC HANT ABILITY AND FITNES S FOR A P AR TICULAR PUR POSE) AR E LIMITED IN DURA TION T O THE ABOVE S IX MONTH W AR RANTY PER IOD. POLARIS F UR THER DISCLAIMS ALL EXPR ESS W AR RANTIES NOT ST A TED IN THIS W ARRANTY .
129 WARRANTY Exported V ehicles EX CEPT WH ERE SPECIFI CALL Y REQU IRE D BY LA W , THERE IS NO W ARRANTY OR SER VIC E BULLETIN COVER AGE ON THIS VEHICL E IF IT IS SOLD OUTS IDE THE COUNTR Y OF THE SELLING DEALER ’S AUTHORIZED LOC A TION.
130 WARRANTY Exported V ehicles How to Ge t Ser vic e If Purchased From A Private Party : If you purcha se a Polaris product fr om a private citiz en outside of the country in whic h t he ve hicle was origina lly purchase d, all warr anty cover age will be denied.
131 INDEX A Ac ce ss ori es 66, 104 ............... ADJ USTMENTS 109- 111 .......... Ag e Restrictio ns 13 ............... Air F ilter Serv ice 90 ............... All Whe el Dr ive 41 ............... Au tom atic Transmissio n 40 ......... Au xiliary B rake 8 5 .
132 INDEX K K-T u r n 60 ...................... L Light Swi tche s 35 ................ Light s 91-94 ..................... Low Bea m Adjus tment 92 .......... Low Ra nge 98 ................... Lubri cat ion Gui de 71 .............. M Main Sw itch 33 .
An important point after buying a device Polaris 9919412 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris 9919412 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris 9919412 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 9919412 you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 9919412 will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 9919412, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris 9919412.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 9919412. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 9919412 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
