Instruction/ maintenance manual of the product Sportsman S Polaris
Go to page of 139
.
W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductive harm. A card containing important A TV safety information should be attached to the owner ’ s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
1 We’ve cr eat ed a web si t e j ust f or YOU! S T echnical ti ps S New product introductions S Event schedules S Parts and Se rvice M anual information S Exciting details about The W ay Out Ch ec k it out.
2 Al l i nf orma t ion i n t his ma nua l i s bas e d on the la t e st produc t dat a and s pe c if ic a t ions a vai l abl e a t the t im e of pri nti ng. Pol ar i s Indus tr i es I nc . re s e rve s the r i ght to make pr oduct c ha nges a nd i mprove me nt s tha t ma y af fe ct illustratio n s o r ex p lan atio ns.
3 WELC O ME Thank you f or purc hasing a Polar is vehicle , and welcome to our wor ld-wide fa mily of Polaris owne rs. W e proudly produc e an exc iting line of utility and r ec re ational pr oducts.
4 VE HICLE IDENTIFICATION NUMBERS The fra me vehic le i dentif ication number ( VIN)(1) a nd engine seria l number ( 2) are impor tant for model identif ication whe n registe ring your ve hicle, when obtaining insur ance , and when or dering replacem ent p arts .
5 TABLE OF CONTENTS WELCO M E 3 ........................................ VEHICL E IDENT IF I CA T IO N NUM BERS 4 ............... T ABL E OF CONT ENT S 5 ............................. SAF ET Y 6 .......................................... CONTROLS 3 6 .
6 SA FETY Safety D ecals and Locations W arning d ecals h ave been placed on th e A TV for your prot ecti on. Read an d fo ll o w th e ins t ruct i on s o n each decal carefu l ly . If a decal bec omes illegible or c omes of f, contac t your P olar is deale r to purcha se a repl acem ent .
7 SA FETY Safety D ecals and Locations IMPR OPER T IRE PRESSUR E OR O VERLO ADIN G can cause loss of contr ol re sulting in SEVERE I NJURY O R DEA TH. TI RE PRESSUR E IN PSI ( KPa) : FRO NT 5 (34,5) REAR 5 (34,5) M AXIMUM WE IGHT CAP ACITY (Gr os s Vehicle W eight) INCLUDIN G MACHINE, DRIVER AND CARGO IS 1200 LBS.
8 SA FETY Safety D ecals and Locations Mov ing parts haz ar d under belt- c lutc h guar d. T o prev ent s er ious injury, do not operate v ehic le w ith guard remov ed. Do not modif y engine or c lut c h. D oing s o c an c aus e part failur e, pos s ible imbalanc e, and exc es s ive engine RP M whic h c an r es ult in s er ious injury or deat h.
9 SA FETY Safety D ecals and Locations ALL WHE EL DRIVE SWITCH Do not push s witc h to engage A WD if the rear wheels are spinning. This m ay c ause sev ere drive s haf t and c lutc h damage. See your Owner ’s Manual. 7079780 7079604 7170509 TRAILER MAX WEIGHT : 1500 LBS.
10 SA FETY Safe Riding G ear Always we ar c lothing suited to the t ype of riding. A TV riding requir es spec ial protec tive clothing for comf ort and to reduce the c hanc e of injury . 1. Helm et Y our he lmet is the most impor tant pie ce of prote ctive ge ar for sa fe r iding.
11 SA FETY Operator S afety Age Restr i ctions This vehi cle is an ADUL T VEHIC LE ONL Y . Operati on is p rohibi ted for anyone under 16 yea rs of age. Know Y our V ehi cle As the opera tor of t he vehic le, you are re sponsible for your per sonal saf ety , the safe ty of others, and the prote ction of our envir onment.
12 SA FETY Operator S afety The f ollowing two pages ide ntify signal wor ds and symbols that appe ar in this manua l. Y our sa fety is involve d when the se words a nd symbols ar e used. Be come f amilia r with their mea nings bef ore re ading the manua l.
13 SA FETY Operator S afety S Rea d this manual a nd all labe ls car efully , and follow the opera ting proce dures de scribe d. S Neve r opera te an A TV without proper instruc tion. T ake a training course . B eginners s hould recei ve traini ng from a certifi ed inst ructor .
14 SA FETY Operator S afety S Alway s hav e the A TV in s pect ed by an au th ori zed P o lari s d eal er if it ’ s been i nvolved i n an accident . S Ne ver oper ate on hills too steep for the A TV or for your abilitie s. Pra ctic e on smalle r hills bef ore a ttempting lar ger hills.
15 SA FETY Operator S afety S W et bra kes may ha ve r educe d stopping ability . T est the br ake s afte r lea ving wa ter . If n ece ssar y , apply them lightly seve ra l times to allow frict i on t o dry o ut t h e pads . S Always che ck for obstac les or people behind the A TV befor e opera t- in g i n revers e.
16 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A TV wit hout pr oper inst ruc t ion. WHA T CAN H APPEN The r isk of an accident is great ly inc reas ed if the oper at or does not know how t o oper ate t he A T V proper ly in diff erent sit uat ions and on diff erent t ypes of t er rain.
17 SA FETY Operator S afety POTENTI AL HAZ A RD Carr ying a pass enger on an A T V . WHA T CAN H APPEN Carr ying a passenger great ly r educes t he operat or ’s ability t o balance and cont r ol t he A T V , which c ould caus e an acc ident and injury t o t he oper at or and/ or pas senger .
18 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing an A T V on paved sur f aces , inc luding sidewalk s, paths , park ing lots , and driv eways.
19 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A TV on public st r eet s, roads or highway s. WHA T CAN H APPEN The A T V could c ollide wit h anot her v ehicle. HOW T O A VOID THE HAZ A RD Never operat e t he A T V on any public st reet , r oad or highway , including dirt and gr avel r oads.
20 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t his A T V wit hout wear ing an approv ed helmet , eye prot ect ion and pr ot ect ive c lot hing. WHA T CAN H APPEN Oper at ing an A T V without an appr oved helm et inc reas es t he ris k of a sev ere head injur y or deat h in t he ev ent of an accident .
21 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A T V af t er consum ing alcohol or drugs . WHA T CAN H APPEN Consumpt ion of alc ohol and/or drugs could ser iously affec t operat or judgm ent . React ion t ime m ay be s lower and operat or balance and perc ept ion could be aff ect ed.
22 SA FETY Operator S afety POTENTI AL HAZ A RD At t empt ing wheelies, jum ps and ot her s t unt s. WHA T CAN H APPEN At t empt ing s tunt s incr eases t he c hance of an acc ident , including an overt ur n. HOW T O A VOID THE HAZ A RD Never att em pt wheelies, jum ps, or ot her stunt s .
23 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o inspec t the A T V bef ore oper at ing. Failur e t o proper ly maint ain t he A TV . WHA T CAN H APPEN Poor m aint enance inc reas es t he poss ibilit y of an acc ident or equipment dam age.
24 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex t ra caut ion when oper at ing the A T V on unf am iliar terrai n. WHA T CAN H APPEN Unfamiliar t errain ma y c ont ain hidden rocks, bumps, o r holes that could caus e loss of cont rol or over tur n.
25 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex tr a caut ion when oper at ing on exces siv ely rough, s lippery or loos e ter rain. WHA T CAN H APPEN Oper at ing on exc essiv ely r ough, slipper y or loos e t err ain could cause los s of t rac t ion or los s of cont r ol, which could r esult in an accident or ov ert urn.
26 SA FETY Operator S afety POTENTI AL HAZ A RD T urning impr operly . WHA T CAN H APPEN Im proper t urns c ould caus e loss of c ont rol and lead t o a c ollision or overt ur n. HOW T O A VOID THE HAZ A RD Always f ollow proper pr ocedur es f or tur ning as descr ibed in the owner ’s manual.
27 SA FETY Operator S afety POTENTI AL HAZ A RD Climbing hills im proper ly . WHA T CAN H APPEN Im proper hill clim bing could caus e loss of cont rol or over tur n. HOW T O A VOID THE HAZ A RD Always f ollow proper pr ocedur es f or climbing hills as desc ribed in the owner ’ s manual.
28 SA FETY Operator S afety POTENTI AL HAZ A RD T raveling downhill im proper ly . WHA T CAN H APPEN Im proper ly des cending a hill c ould cause los s of c ontr ol or overt ur n. HOW T O A VOID THE HAZ A RD Always f ollow proper pr ocedur es f or tr aveling down hills as descr ibed in t he owner ’s manual.
29 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly c ross ing hills and t ur ning on hills. WHA T CAN H APPEN Im proper ly cr oss ing or turning as hills could caus e loss of c ontr ol or overt ur n.
30 SA FETY Operator S afety POTENTI AL HAZ A RD St alling, rolling bac kwards or impr operly dis mount ing while climbing a hill. WHA T CAN H APPEN The v ehicle c ould over t urn. HOW T O A VOID THE HAZ ARD Maint ain st eady speed when climbing a hill.
31 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly operat ing over obs tac les. WHA T CAN H APPEN Oper at ing over obst acles could c ause loss of cont rol or over tur n. HOW T O A VOID THE HAZ A RD Bef ore oper at ing in a new area, chec k f or obst acles .
32 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A T V t hr ough deep or f ast - f lowing wat er . WHA T CAN H APPEN T ires may f loat , caus ing loss of t r act ion and loss of cont r ol, which could lead t o an ac cident or ov ert ur n.
33 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A TV wit h impr oper t ires , or wit h improper or unev en tire pre ssure. WHA T CAN H APPEN Use of impr oper t ires , or oper ation of t he A TV wit h impr oper or uneven t ire pr ess ure, could c ause los s of cont r ol or ac cident .
34 SA FETY Operator S afety POTENTI AL HAZ A RD Ov erloading t he A TV or c arr ying/ t owing car go impr operly . WHA T CAN H APPEN Ov erloading and t owing c an cause c hanges in v ehicle handling, which could lead t o los s of cont r ol or an ac cident .
35 SA FETY Operator S afety Oper at ing a damaged A T V can r esult in an ac cident wit h ser ious injury or deat h. A f ter any ov ert ur n or accident , hav e a qualified serv ice dealer inspec t t he ent ir e mac hine for poss ible damage, including (but not lim ited t o) brak es, t hrot t le and st eer ing systems.
36 CONTROLS Engine E lectr ical Switches Mod e/ Rev erse O v erri d e S wi tch (1) - This veh icle is e quipped with a re verse spee d limiter system. T o gain a dditional powe r while bac king, depr ess the override switc h. NOTE: The ove rride switc h also allows ac tivation of All Wh eel Dr ive (A WD) in re verse , if the A WD switc h is on.
37 CONTROLS Throttle Lever Eng i ne sp eed an d veh icl e moveme nt are c ontrolle d by pre ssing the t hrottle le ver (1) . The throttle le ver is spring lo aded .
38 CONTROLS Light S witches The light switch is loc ated on the left ha ndleba r . It’ s used to turn the lights on and of f and to switc h the lights fro m HI to LO. NOTE: The lights won’ t work unle ss the key is in the ON position and the shut-of f s w i t c hi si nt h e RUN position.
39 CONTROLS Master Cylinder The bra ke fluid in the master cylinde r (1) , which is loca ted on the lef t handleba r , should be chec ked before each ri de. T he fl u id lev el ca n be see n through an indic ator window (2) on the top of the master cylinde r .
40 CONTROLS Park in g Bra ke Setting the P arking Br ake 1. Place the tr ansmission in first gea r (or in P ARK if equipped). 2. S qu eeze and rel ease t h e brak e leve r (1) two or thr ee time s, then sq ueeze an d h ol d . 3. Push the par k brake lock ( 2) forw ard to engage the bra ke.
41 CONTROLS Auxiliary Brake Y our Polar is A TV ha s an auxilia ry brak e (1) for a dded saf ety . It’ s locate d on the inside of the right floor board and is oper ated b y the right foot. The auxilia ry brake serv es as a b acku p t o t h e m ain bra ke system if the main system be comes inope ra tive.
42 CONTROLS Choke The choke a ssists i n starting a cold engine . R ef er to the engine star ting proc edure on page 53 for c orre ct choke and throttle settings during star ting. Fuel V alve The fu el val ve (1 ) i s l o cated on th e l eft s i de pane l.
43 CONTROLS Autom atic T r ansm ission Gear Selector The tra nsmission gear se lector ( 1) is l oca ted on the right side of the vehic le. S hift pa tterns va ry , depe nding on your model.
44 FEATURE S All W heel Dr ive (A W D ) System Po l aris 4-wh eel dri ve A TVs are equippe d with a unique , Polar is-ex clusive, A WD syste m, whic h is activa ted by a switc h (1) on the r ight handlebar . When the s w i t c hi so f f ,t h eA T Vi si n2w h e e l drive a t all times.
45 FEATURE S In s tru men t Clu st er Y our A TV is e quipped with a n instrume nt cluster tha t sense s vehic le spee d from the right front whe el. The instrume nt cluster measur es distanc e in mile s as we ll as hours of opera tion.
46 FEATURE S In s tru men t Clu st er Ri der Infor ma tion Ce nter The ride r infor mation ce nter is loca ted in the instr ument cluste r . All segme nts will light up for 2.
47 FEATURE S In s tru men t Clu st er Ri der Infor ma tion Ce nter The r ider informa tion ce nter h as 4 standa rd mode s: Mode 1 - Odometer Mode 2 - T ripmete r Mode 3 - T otal S ervic e Hours Mode 4 - T achome ter The re verse ove rride button on the left handle bar is also the mode button .
48 FEATURE S In s tru men t Clu st er Ri der Infor ma tion Ce nter Dia gnos tic Mode The diagnostic mode is for inf ormationa l purposes only . P lease r eturn your A TV to your deale r for all major r epa irs. As long as the gauge is in the diagnostic mode, the wrenc h icon will re main lit.
49 FEATURE S In s tru men t Clu st er Ri der Infor ma tion Ce nter Dia gnos tic Mode S cr een 5: Progra mmable se rvice inte rva l The purpose of the progr amma ble servic e interv al is to provide the consume r and dea ler with a conve nient reminde r for routine mainte nanc e.
50 OPERATION Fuel Safety Gas oline is highly f lammable and ex plosiv e under c ert ain condit ions. S Always exer cis e ext rem e caut ion whenev er handling gasoline. S Always ref uel wit h t he engine st opped, and out doors or in a well vent ilat ed area.
51 OPERATION Br eak -In Per iod The br eak -in per iod for your ne w Polaris A TV is define d as the first te n hours of oper ation, or the time it takes to use the first two full tanks of gasoline . No single a ction on your pa rt is as importa nt as following the proc edure s for a prope r brea k-in.
52 OPERATION Pr e - Ride Inspection Use the f ollowing che cklist to verif y that your vehic le is in proper wor king condition be fore each use. Item/Inspection Pr oced ure 1. T ires - Chec k condition and pr essure s. 2. Fuel tank a nd engine oil level - Fill both to their pr oper le vels.
53 OPERATION Star ting the Engi ne S tar ting a Col d Engi ne 1. Place the tr ansmission in neutral (or P AR K if equipped) and lock the par king brake . 2. T urn the fuel tank valve on. 3. Sit on the vehicle and pull the choke knob out until it stops (1) .
54 OPERATION Star ting the Engi ne S tar ting a W ar m Engi ne W ar m engines do not normally re quire the use of the choke . Using the choke c an cause the spa rk plug to become we t fouled. 1. Position the vehicle on a le vel surfa ce with the tra nsmission in neutr al (or P ARK if equipped) .
55 OPERATION Hauling Cargo Y our A TV ha s been de signed to ca rry or tow a c erta in amount of load. Always r ead a nd under stand the load d istribution war ning labe ls on the veh icl e, an d nev er exceed t he wei gh t cap ac ities outline d in the sp ecifi cat i on s s ecti o n of t he own er ’ s m anu al an d on t h e safety d ecal s.
56 OPERATION Hauling Cargo Hauling cargo im proper ly c an alt er v ehicle handling and m ay cause los s of c ontr ol or br ake ins t ability and res ult in serious injury or deat h. Alway s f ollow t hes e precaut ions when hauling car go: S REDUCE SPEED AND ALLO W G REA T ER DI ST ANCES F O R BRAKING WHEN HAULING C ARGO .
57 OPERATION Driving Safely Driving Pr ocedu res 1. Sit upright with both feet on the footre sts and both hands on the handle bars. 2. Start the engine a nd allow it to warm up, the n shift the tra nsmission into gea r . 3. Check your surr oundings and determine your path of tra vel.
58 OPERATION Driving Safely Making T urns Y our A TV is e quipped with a solid rea r a xle, which dr ives both re ar whe els equa lly at a ll times. This mea ns that the whee l on the outside of t he t u rn m u st t ravel a g reater d i st an ce th an t h e i ns id e wh eel when turning a nd the inside tir e must slip tra ction slightly .
59 OPERATION Driving Safely Dr iving o n Slippery S urfaces Whenev er rid i ng on s l i pp ery su rfaces su ch as wet t rai ls or l oo se grav el, or du rin g freezi ng weat her , fol l ow t hes e precaut i on s : 1. Slow down when e ntering slippe ry are as.
60 OPERATION Driving Safely T raveling Uphill Whe nev er tra veling uphill, follow these pr ecauti on s : 1. Alwa ys tra vel stra ight uphill. 2. A void steep hills ( 25 _ maximum) . 3. Kee p both fee t on the footre sts. 4. T ransf er your weight forw ard.
61 OPERATION Driving Safely Sidehilling Sidehilling ca n be a da ngerous type of driving a nd should be avoide d if at a ll possible. If you do e nter into a situation w here sidehilling is neces sary , fol l ow th ese p recau ti o ns : 1. Sl ow down.
62 OPERATION Driving Safely T raveling Downhill Whe neve r desce nding a hill, follow the se pr ecaut i o ns : 1. P roceed d i rectl y d ow nh ill. 2. T ra nsfer your we ight to the rea r of the vehic le. 3. Sl ow down. 4. Apply the brakes slightly t oa i di ns l o w i n g .
63 OPERATION Driving Safely T urning A r ound on a Hi ll If the ve hicle sta lls while climbing a hill, never ba ck it down the hill! One mane uver tha t can be used when you must tur n around while climbing a hill is the K-turn: 1. Stop and lock the pa rking bra ke while kee ping body weight uphill.
64 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV c an oper ate thr ough water with a maximum re comme nded depth e qual to the bottom of the footr ests (1). Follow th ese p roced ures when oper ating through water: 1. De termine w ate r depths a nd curre nt bef ore cr ossing.
65 OPERATION Driving Safely Dr iving Over Ob stacles Be al ert! Lo ok ah ead and l earn t o read th e terrai n yo u’re t ravel i ng o n. Be con s tan t l y alert fo r hazards s uch as l o gs , r ock s and l o w hang i ng bran ches . Sever e injury or deat h can r esult if your vehic le com es in cont ac t with a hidden obs t acle.
66 OPERATION Driving Safely Dr iving in Reverse F ol l ow th ese precau t io ns when o perat i ng i n rev erse: 1. Alwa ys avoid bac king downhill. 2. Back slowly . 3. Whe n in reve rse , apply the bra kes lightly for stopping. 4. A void t urning a t sh arp angl es i n rev erse.
67 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible. If it’ s unavoida ble, follow th es e precau ti o ns : 1. T urn the engine of f. 2. Place the tr ansmission in low range ( or park if equippe d).
68 EMISSION C O NT RO L SYSTEMS Noise E m ission C ontrol S ystem T AM PER ING WITH NOIS E CONTR OL S YS TEM P R OHIBITED! U.S . F ede ral law prohibits the following acts or the causing the reof: (1).
69 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Care ful per iodic maintena nce will help keep your vehic le in t he saf est, most relia ble c ondition. Inspe ction, adjustment a nd lubrica tion of importa nt components ar e expla i ned i n the periodic maintena nce sche dule.
70 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Hours of ope ration a re ba sed on a 10 mph aver age. If servic e is due a t 20 hours, the e quivalent odome ter re ading w ould be 200 miles. P erform al l serv i ces at whi chever readi ng i s reached fi rst .
71 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Item Hours/ Mile s Fr equency Remarks " Air box sediment tube Pr e-Ride Pr e-Ri de Drai n deposit s whenever visi ble Headlam p Pr.
72 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Item Hours/ Mile s Fr equency Remarks Carbur etor fl oat bowl 50 hr s. 6 mont hs Drai n bowl peri odical ly and pri or t o stor age J Throt tle Cabl e/ ETC Swit ch 50 hr s. 6 mont hs Inspect ; adjust; l ubr icat e; r eplace if necessar y L Choke (enr icher) cable 50 hr s.
73 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Item Hours/ Mile s Fr equency Remarks " Rear axle 50 hr s. 6 mont hs In spect beari ngs; lube J L Igni t ion T im ing 100 hr s.
74 MAINTENANCE AND LUBRICATION Per i odic Maintenance Recor d Use t he fo l lo wi ng chart to record peri od i c mai n ten ance. Maintenance In t erval Perfo rmed Se rv icing Date Se rv icing Dealer or Pe rs on Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.
75 -N O T E S -.
76 MAINTENANCE AND LUBRICATION Lubr ication G uide NOTE: Hour s in t he fr equenc y column a re ba sed on 10 mph aver age. If se rvice is due at 20 hours, the equivale nt odometer re ading would be 200 mile s. Perf orm a ll servic es a t whic heve r re ading is r eached firs t .
77 MAINTENANCE AND LUBRICATION Lubr ication G uide (Fig. 1 ) (Fig. 4 ) (Fig. 2 ) (Fig. 3 ) (Fig. 5 ) (Fig. 1 ) (Fig. 2 ) (Fig. 6 ).
78 MAINTENANCE AND LUBRICATION Pr em i um 4 S yntheti c Lubr icant Polaris Pre mium 4 All S ea son synthetic e ngine oil has be en spe cially for mulated f or use in P olar is 4-c ycle engine s.
79 MAINTENANCE AND LUBRICATION Oil Check The oil dipstick and fill tube (1) ar e locate d on the left side of the vehic le. 1. Position the A TV on a level surf ace. 2. Start the engine and let it idle for 20-30 se conds. 3. Stop the engine. Remove the dipstick a nd wipe it dry w ith a clean cl o t h.
80 MAINTENANCE AND LUBRICATION Oil and Filter Change The r ecomme nded oil c hange inte rva l is 100 hours, 1000 miles, or eve ry six months, whic heve r come s fir st. Suggested br ea k-in oil cha nge is a t 20 hour s, 200 miles, or one month, w hiche ver comes first.
81 MAINTENANCE AND LUBRICATION Oil Change (400/500) 7. Plac e shop towe ls bene ath the oil filte r . Using an oil f ilter w renc h, turn the filte r (1) counte rcloc kwise and re move. 8. Lubric ate the gaske t on the new filte r with a film of new engine oil.
82 MAINTENANCE AND LUBRICATION Oil Change (600/700) 1. P lace t h e veh i cle o n a lev el su rface. 2. Run the engine for two to thre e minutes until wa rm. Stop the engine . 3. Clean the ar ea a round the drain plug. 4. Place a dr ain pan bene ath engine c rankc ase and re move the dra in plug.
83 MAINTENANCE AND LUBRICATION T r ansm ission Oil (400/500) The tra nsmission oil level should b e chec ked e very six months or 1000 miles ( 1600 km), whiche ver c omes fir st. T ra nsmission oil should be cha nged annua lly . W e re commend the use of Polar is P re mium Synthetic Gea rca se Lubrica nt.
84 MAINTENANCE AND LUBRICATION Front Gear case Oil (400/500) The f ront gear case lubrica nt level should be c hec ked eve ry six months or 1000 miles (1600 km), whiche ver come s first. F ront gea rca se oil should be change d annually . Use Polaris Premium Synthetic Gea rca se Lube (or GL5 80-90 weight gear lube ).
85 MAINTENANCE AND LUBRICATION T r ansm ission Oil (600/700) The tra nsmission oil level should b e chec ked e very six months or 1000 miles ( 1600 km), whiche ver c omes fir st. T ra nsmission oil should be cha nged annua lly . W e re commend the use of Polar is P re mium Synthetic Gea rca se Lubrica nt.
86 MAINTENANCE AND LUBRICATION Front Gear case Oil (600/700) The f ront gear case lubrica nt level should be c hec ked eve ry six months or 1000 miles (1600 km), whiche ver come s first. F ront gea rca se oil should be change d annually . W e rec ommend the use of Polar is Premium Hub Drive Fluid.
87 MAINTENANCE AND LUBRICATION Rear Gearcase Oil (600/700) The r ear gea rca se lubric ant leve l should be che cked e very six months or 1000 miles (1600 km), whiche ver come s first. Rear ge ar case oil should be change d annually . Use Polar is P re mium S ynthetic Ge arc ase Lube (or GL5 80-90 weight gea r lube).
88 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Coolant Level The r ec overy bottle (1) is loc ated on the left s id e of th e m achi ne. T o acces s th e re cover y bottle, remove the lef t side pane l as outline d on page 93.
89 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Radiator Coolant Level NOTE: This pr ocedur e is re quired only if the c ooling system has be en dra ined for mainte nanc e and/or re pair . Howe ver , if the rec overy bottle has run dry , the leve l i n the radiator should be inspe cted a nd coolant added i f neces sary .
90 MAINTENANCE AND LUBRICATION Fr ont Br ake The front bra kes are hydr aulic disc bra kes. They’r e activa ted by moving the brake le ver toward the handle bar . These br akes ar e self -adjusting. The fo l lo wi ng checks are recom m end ed t o keep t h e brak e sy st em in good oper ating condition.
91 MAINTENANCE AND LUBRICATION Rear Br ake The re ar bra ke is a hydraulic disc bra ke and is act i vat ed b y th e sam e l ev er t hat act iv at es the front bra ke system. The rea r brake system is self -a djusting and re quires no mainte nanc e other than per iodic chec ks of th e pad s fo r wear .
92 MAINTENANCE AND LUBRICATION T oe A li gnm ent Use the following proce dure to chec k the t oe alignme nt of t he vehic le. The re comme nded toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set t he handle bars in a stra ight-ahe ad position. NOTE: The st eerin g fro g can be us ed as an i nd i cato r of whether the ha ndlebar s are stra ight.
93 MAINTENANCE AND LUBRICATION Si de Pa nel Rem oval NOTE: Side panel r emoval ma y be dif ficult until the locking ta bs and receiv ers hav e been sn app ed and un s napp ed a few times. 1. Remove the sea t. 2. Grasp the rea r of the side pan el n ear t he rear cab .
94 MAINTENANCE AND LUBRICATION T ir e T r ead De pth Alway s repl ace ti res when t read depth is wor n to 1/8 ″ (.3 cm) or less. See illustr ation. Wheel Rem oval 1. Stop the engine, plac e the transmission in gea r (or in P ARK if equipped) and lock the par king brake .
95 MAINTENANCE AND LUBRICATION Wheel Installation 1. Place the tr ansmission in gear (or in P AR K if equipped) and loc k the parking br ake. 2. P lace t h e wh eel o n t h e wheel hu b wi t h t he v al ve s tem towar d the outside and rota tion ar rows on the tire pointing toward f orward rota tion.
96 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service 1. Rem o ve t h e seat , rel eas e t he air box cove r clips, and re move the air box cover . 2. Loosen the cla mp and re move the filte r . 3. Remove the fa bric type pre -filte r (1) f rom the main filte r (2).
97 MAINTENANCE AND LUBRICATION Lights Whe n ser vicing a ha logen lamp, don’ t touch the la mp with bare finger s. Oil fr om your skin le ave s a re sidue, ca using a hot spot tha t will shorten the life o f the lamp. Headlight L amp Replacem ent 1.
98 MAINTENANCE AND LUBRICATION Lights High Be am Ad just ment The h eadlight be am ca n be a djusted to any position d esire d by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a leve l surfa ce with the hea dlight appr oximate ly 25 ft.
99 MAINTENANCE AND LUBRICATION Lights Headlight Hou sing Replacement 1. Remove the two screws on the lower front corne rs of t he headlight pod. 2. Usi ng a sm al l fl at -bl ade screwd ri ver , p us h in o n t he lo ck t ab through the two small openings at the f ront of the hea dlight pod.
100 MAINTENANCE AND LUBRICATION Lights Lower Headlam p Removal / Installation 1. T urn the bac k of the he adlight har ness (1) in a cloc kwise direc tion. 2. Pull the ha rness assembly out f rom the headlight asse mbly . 3. Remove the h ead lamp and re plac e with a new he adla mp.
101 MAINTENANCE AND LUBRICATION Spar k P l ugs S Use BKR5E spark plugs f or the Sportsman 400 a nd 500. S Use RC7YC spark plugs for the Sportsman 600 a nd 700. S Proper ele ctrode ga p i s . 035 ″ (.90 mm). S Spark plug torque is 18 ft. lbs. (24 Nm).
102 MAINTENANCE AND LUBRICATION V eh ic le Imme rs io n If it’ s impossible to take your A TV to a deale r befo re star ting it, follow the steps outlined below . 1. Move the A TV to dry land or at the very lea st, to wate r below the footr ests. 2.
103 MAINTENANCE AND LUBRICATION Spar k A r r estor Use t he fo ll o win g p roced ure t o peri od ical l y p urge accum ul at ed carb on fr om the exha ust pipe/muf fler . 1. Remove the ar restor c lean- out plug (1) fr om the bottom of t he muf fler .
104 MAINTENANCE AND LUBRICATION PV T S ystem The basic ope ration of the Polaris PVT system is dependent on engine sp eed an d v ehi cl e to rqu e requ irem en ts . As engi n e sp eed i n creases , th e for ce exe rted on the movable drive shea ve by t he flyweights also incr ease s.
105 MAINTENANCE AND LUBRICATION PV T S ystem PVT Dryi n g There m ay be so me i ns tan ces when wat er i s accid ent l y i ng est ed i nt o the PVT system. Use the following instruc tions to dry it out before oper ating: 1. Remove the dr ain plug and allow the wa ter to dra in.
106 MAINTENANCE AND LUBRICATION Batter y Y our A TV ma y have eithe r a se aled ba tter y , which re quire s little mainte nanc e, or a conventiona l batter y . Keep the conve ntional batte ry term i nal s and co nn ecti o ns free of corros i on . If clean i ng i s neces sary , re move the cor rosion with a stif f wire b rush.
107 MAINTENANCE AND LUBRICATION Batter y Batt ery Remo val 1. Disconne ct the hold- down strap holding the batte ry in position, and re move batter y cover . 2. On conventiona l batter ies, remove the batte ry vent tube. 3. Dis con nect t he b lack (neg ati v e) bat t ery cab le fi rs t .
108 MAINTENANCE AND LUBRICATION Batter y Batter y S torage When th e veh i cl e is p laced i n s t orag e for th ree m on t hs or m o re, th e batte ry should be r emoved, store d out of the sun in a c ool, dry plac e and te sted monthly . B ef ore r eusing, take the batte ry to your de ale r for testing a nd rec har ging.
109 MAINTENANCE AND LUBRICATION Batter y Batter y Char ging (Sealed B attery) For a re fre sh char ge, follow all instruc tions ca ref ully . 1. Chec k the batter y voltage with a voltme ter or multime ter . A fully cha r ged ba tter y will register 12.
11 0 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry power outle ts provide 12V powe r for oper ating acces so ries such a s hand held spot lights. Acc essory outle ts are ava ilable f or all mo del s . P ol ari s als o h as a wi d e rang e of ad di t io nal acces so ries ava ilable f or your A TV .
111 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s Clean t he Exterio r Make nec essar y repa irs a nd then cle an the A TV thoroughly with mild soap a nd war m wate r to re move all dirt a nd grime. Don’ t use harsh dete r gents or high pressur e washer s.
11 2 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s Fog the E ngine 1 . Remove the spa rk plug an d add 2-3 table spoons of Premium 4 S yn th et i c 0W4 0 en gi n e oi l .
11 3 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s Batte r y Mai nte na nc e (Conve nti ona l) Remove the ba tter y and a dd distilled wa ter to the prope r lev el. Do not use tap w ater , wh i ch may co nt ai n m in eral s t hat red uce bat t ery l if e.
11 4 ADJUSTME NTS Cam ber and Caster The ca mber and ca ster a re non-a djustable . Rear S pr ing The re ar shock absor ber spring is adjuste d by rota ting the ad juster ( 1) eit h er cl ock wi se o r counte rcloc kwise to i ncr ease or decreas e sp ri ng t ens i on .
11 5 ADJUSTME NTS Car bur etor / Idl e RP M If the e ngine idle speed is not satisfa ctory , and all other conditions ar e favora ble, the carbur etor can b e adj us t ed. 1. W arm up the engine by running the vehic le for a pproximate ly five minutes.
11 6 ADJUSTME NTS Thr ottle Cabl e Fr eeplay Thr ottle ca ble fre epla y is adjusted at the handle bar . 1. Slide the boots (1) of f the inline cab le adjuster sle eve ( 2). Loosen the adjuste r locknut (3). 2. T urn the adjuste r until 1/16 ″ to 1/8 ″ freepl ay is achi ev ed at t he th um b l ev er .
11 7 TROUB LES HOOTIN G Dr ive Belt an d Cover Pr ob lems Po ssi b l e Cause Solution Dr ivi ng t he A TV onto a p ick u p o r tall trailer in hi gh ra nge . Shi ft tr a nsm is s ion t o low ra nge duri ng loa ding of the A TV t o pre ve nt bel t burni ng.
11 8 TROUB LES HOOTIN G Contac t your P olar is deale r for ser vice if you’ re unable to identif y solutions using the follow ing char ts. Engine Doesn’t T urn Over Po ssi bl e Cause Sol uti o n Trip p ed circu it b reak er Reset th e b reak er Lo w battery v o ltage Re cha r ge ba tt er y to 12.
11 9 TROUB LES HOOTIN G Engine Backfir es Po ssi bl e Cause Sol uti o n W ea k spa rk f rom s pa rk pl ugs In sp ect, clean and /o r repl ace sp ark p lu g s In co rrect spark p lu g g ap o r h eat ra.
120 TROUB LES HOOTIN G E ngine St ops or Loses P ower Po ssi bl e Cause Sol uti o n Out of fuel Tu rn fu el valv e to reserve, refuel Ki nked or plugge d fue l ve nt li ne In sp ect an d rep lace W at.
121 POLARIS PRODUCTS Part No. Descri pti on Engine Lubr icant 2870791 Fogging O il (12 oz. Aer osol ) 2871281 Engine O il (qt . ) Pr emium 4 Synthet ic 0W -40 ( 4-Cycl e) 2871844 Engine O il (gal .) Pr emi um 4 Synthet ic 0W -40 ( 4-Cycl e) Gear case / T ransmi ssi on Lubri cants 2871477 Prem ium Synt hetic G earcase Lubr icant ( 1 gal.
122 SPECIFIC AT IO NS SPORT SM AN 40 0 Gro ss V eh icle W eigh t 1200 l bs. /544 kg T owi ng Capa c it y 1225 l bs. /556 kg Hi tc h T ongue Capa ci ty 120 l bs. /54 kg ( Rea r ra ck w ei ght a nd tongue weig h t n o t to exceed 1 8 0 lb s./8 1 .6 k g ) F ro n t R ack C ap acity 90 l bs.
123 SPECIFIC AT IO NS SPORT SM AN 40 0 Shi ft T ype Side Leve r (H igh, Low , Neut ra l, Re ve rs e ) Gear R ed u ctio n - L o w 8.27/ 1 Ge ar Re duct ion - Reve rs e 5. 17/ 1 Gear R ed u ctio n - F o rw ard 3.34/ 1 Driv e R atio - F ro n t 2:1 Driv e R atio - F in al 3.
124 SPECIFIC AT ION S SPORT SM AN 50 0 Gro ss V eh icle W eig h t 1200 lbs ./ 544 kg Hitch T o w in g R atin g 1 225 l bs ./ 556 k g Un b raked Trailer T o w in g C ap acity * 1786 lbs ./ 810 kg Hi tc h T ongue Capa c it y 120 lbs ./ 54 kg (Re a r r a ck w ei ght a nd tongue weig h t no t to ex ceed 1 8 0 lb s.
125 SPECIFIC AT IO NS SPORT SM AN 50 0 Driv in g S y stem T y p e EBS Shi ft T ype Side Leve r (H igh, Low , Neut ra l, Re ve rs e ) Gear R ed u ctio n - L o w 8.27/ 1 Ge ar Re duct ion - Reve rs e 5. 17/ 1 Gear R ed u ctio n - F o rw ard 3.34/ 1 Driv e R atio - F ro n t 2:1 Driv e R atio - F in al 3.
126 SPECIFIC AT IO NS SPORT SM AN 60 0 Gro ss V eh icle W eigh t 1240 l bs. /563 kg F u el Cap acity 4. 75 ga l. /18 l T owi ng Capa c it y 1500 l bs. /681 kg Hi tc h T ongue Capa ci ty 1 5 0 lb s./6 8 .1 k g (R ear rack capacity an d t ongue we ight not t o e x ceed 2 0 0 lb s.
127 SPECIFIC AT IO NS SPORT SM AN 60 0 Shi ft T ype Side Le ver (Hig h , Lo w , N eu tral, R ev erse, Park ) Gear R ed u ctio n - L o w 7.5/ 1 Ge ar Re duct ion - Reve rs e 5. 1 1/1 Ge ar Re duct ion - High 3.09/ 1 Driv e R atio - F ro n t: 3.82/ 1 Driv e R atio - F in al 3.
128 SPECIFIC AT IO NS SPORT SM AN 70 0 Gro ss V eh icle W eigh t 1240 l bs. /563 kg F u el Cap acity 4. 75 ga l. /18 l T o w in g R atin g 1500 lbs ./ 681 kg Un brak ed Trailer T o w in g C ap acity * 1914 l bs. /868 kg F ro n t R ack C ap acity 100 l bs.
129 SPECIFIC AT IO NS SPORT SM AN 70 0 Shi ft T ype Side Le ver (Hig h , Lo w , N eu tral, R ev erse, Park ) Gear R ed u ctio n - L o w 7.5/ 1 Ge ar Re duct ion - Reve rs e 5. 1 1/1 Ge ar Re duct ion - High 2.89/ 1 Driv e R atio - F ro n t: 3.82/ 1 Driv e R atio - F in al 3.
130 WARRANTY LIM IT ED W ARRANTY Polaris Sa les Inc ., 2100 Highway 55, Medina, MN 55340, gives a S IX MONTH LIMITED W ARRANTY on all components of the Polaris All T errai n V ehi cl e (A T V) agai ns t defect s i n mat eri al or wo rkm ans hi p .
131 WARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIM IT A T IONS OF W ARRANT IES AND REM EDIES The Polaris limited war ranty e xcludes a ny fa ilures tha t are not cau sed by a de fec t in mater ial or workma nship. This warr anty does not cove r accid ent al d amag e, n orm al wear and t ear , ab us e or i m p rop er han dl i ng .
132 WARRANTY ALL IMPLIED W ARR ANTIES (INC LUDING B UT NOT LIMITED T O THE IMP LIED W AR R ANTIES OF MER C HANT AB ILITY AND FITNES S FOR A P AR TIC ULAR P UR P OSE) AR E LIMITED IN DURA TION TO THE ABOVE SIX M ONTH W AR RANTY P ER IOD. POLAR IS FUR THER DIS CLAIMS ALL EXPR ES S W ARR ANTIES NOT ST A TED IN THIS W ARR ANTY .
133 WARRANTY Exported V ehicles EX CEPT W HER E SPECIFI CAL L Y REQ UI RED BY LA W , THE RE IS NO W ARR ANTY OR S ER VICE B ULLETIN C OVERAGE ON THIS VEHIC LE IF IT IS S OLD OUTSIDE THE C OUNTR Y OF THE SELLING DEALER ’S AUTHORIZED LOC A TION.
134 WARRANTY Exported V ehicles How to G e t Se rv i ce If Purchased From A Private Party: If you purch ase a Polaris produc t from a private c itizen outside of the countr y in which the ve hicle w as origina lly purcha sed, all war ra nty cove rage will be denie d.
135 INDEX A Accessori es 110 .................... ADJUSTM ENTS 11 4 - 11 6 ........... Age R estrictio ns 1 1 ................. Air F ilter Service 96 ................ All W h ee l Dr i v e 4 4 ................. Autom atic T ransmission 43 ...........
136 INDEX M Main S witch 3 6 .................... MAINTENANCE AND LUBRICA TI ON 6 9 - 11 3 .... Mai ntenance Record 74 .............. Maki ng T urns 58 ................... Master C ylinder 39 ................. N Noi se Em ission Cont rol System 68 ...
P art No. 9918540 Rev 04 PRINTED IN THE USA W ARNING Impr oper vehicle use can r esult in SEVERE INJUR Y or DEA TH. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND W ARNINGS.
An important point after buying a device Polaris Sportsman S (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 Sportsman S 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 Sportsman S - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris Sportsman S you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris Sportsman S will certainly help you make a decision on the purchase.
If you already are a holder of Polaris Sportsman S, 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 Sportsman S.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris Sportsman S. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris Sportsman S 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
