Polaris Sportsman S Owner's Manual
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Polaris Sportsman S Owner's Manual

Polaris Sportsman S Owner's Manual

Polaris 2004 atv owner's manual
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Summary of Contents for Polaris Sportsman S

  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV 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.
  • Page 3 We’ve created a web site just for YOU! Check it out... www.polarisindustries.com/owner Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out...
  • Page 4 All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

  • Page 5: Welcome

    S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...

  • Page 6: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced.

  • Page 7: Table Of Contents

    EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION TROUBLESHOOTING POLARIS PRODUCTS SPECIFICATIONS WARRANTY ........

  • Page 8: Safety

    Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

  • Page 9: Safety Decals And Locations

    Safety Decals and Locations S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter. S Operation of this vehicle without engine breather filter(s) can cause engine damage.
  • Page 10 SAFETY Safety Decals and Locations 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. S DO NOT TOW FROM RACK OR BUMPER.
  • Page 11 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. 7079780 Canadian Certification Decal SAFETY MANUFACTURED BY: POLARIS IND INC. DATE: VIN: 7078470 7170911 7170509...

  • Page 12: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance 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.

  • Page 13: Operator Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV 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.
  • Page 14 SAFETY Operator Safety 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.
  • Page 15 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.
  • Page 16 SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

  • Page 17: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 18 ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. WARNING WARNING...
  • Page 19 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 20 SAFETY Operator Safety POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control, accident, and/or injury.
  • Page 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads.
  • Page 22 SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
  • Page 23 Operator Safety POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
  • Page 24 SAFETY Operator Safety POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING...
  • Page 25 Operator Safety POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition.
  • Page 26 SAFETY Operator Safety POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 27 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.
  • Page 28 SAFETY Operator Safety POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds.
  • Page 29 SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill.
  • Page 30 SAFETY Operator Safety POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill.
  • Page 31 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.
  • Page 32 SAFETY Operator Safety POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
  • Page 33 Operator Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
  • Page 34 SAFETY Operator Safety POTENTIAL HAZARD Operating the 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 or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
  • Page 35 Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.
  • Page 36 SAFETY Operator Safety POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.
  • Page 37 Operator Safety Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.

  • Page 38: Controls

    CONTROLS Engine Electrical Switches Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system.

  • Page 39: Throttle Lever

    This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

  • Page 40: Brake Lever

    CONTROLS Light Switches The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switch is in the RUN position.

  • Page 41: Master Cylinder

    NOTE: When checking the fluid level, the ATV must be on level ground with the handlebars straight. If the fluid level is low add DOT 3 brake fluid only. See page 121 for the part numbers of Polaris products. After opening a bottle of brake fluid, always discard any unused portion.

  • Page 42: Parking Brake

    CONTROLS Parking Brake Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Place the transmission in first gear (or in PARK if equipped).

  • Page 43: Auxiliary Brake

    The rear wheels may skid and slide sideways, causing loss of control and serious injury or death. Your Polaris ATV has an auxiliary brake (1) for added safety. It’s located on the...

  • Page 44: Fuel Valve

    CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions: OFF: For vehicle storage and when transporting.

  • Page 45: Belt Life

    Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park (Sportsman 600/700 only) To shift into HIGH or PARK on the Sportsman 600 or 700, you must first apply the auxiliary brake to activate the high/park lock-out mechanism.

  • Page 46: Features

    FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, 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.

  • Page 47: Instrument Cluster

    Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph.

  • Page 48: Rider Information Center

    If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - As the shift lever is moved, this indicates the...
  • Page 49 FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button.

  • Page 50: Diagnostic Mode

    FEATURES Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.
  • Page 51 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours.

  • Page 52: Operation

    OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 53: Break-In Period

    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 full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.

  • Page 54: Pre-Ride Inspection

    OPERATION Pre-Ride Inspection If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your vehicle is in proper working condition before each use.

  • Page 55: Starting The Engine

    Starting the Engine Starting a Cold Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Place the transmission in neutral (or PARK if equipped) and lock the parking brake.

  • Page 56: Starting A Warm Engine

    Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

  • Page 57: Hauling Cargo

    OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
  • Page 58 OPERATION Hauling Cargo Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 59: Driving Safely

    Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 60: Making Turns

    OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

  • Page 61: Driving On Slippery Surfaces

    Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 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.

  • Page 62: Traveling Uphill

    OPERATION Driving Safely Traveling Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6.
  • Page 63 Driving Safely Sidehilling Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible.

  • Page 64: Traveling Downhill

    OPERATION Driving Safely Traveling Downhill Whenever descending a hill, follow these precautions: 1. Proceed 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 operation of the auxiliary brake in the event loss of normal service brakes occurs.

  • Page 65: Turning Around On A Hill

    Driving Safely Turning Around on a Hill Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.

  • Page 66: Driving Through Water

    OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2.

  • Page 67: Driving Over Obstacles

    Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 68: Driving In Reverse

    Use with caution. Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Your Polaris ATV is 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. Open the throttle just enough to maintain a desired speed.

  • Page 69: Parking On An Incline

    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in low range (or park if equipped). 3. Set the parking brake. 4.

  • Page 70: Emission Control Systems

    Do not touch hot exhaust system components. Use caution when traveling through tall grass, especially dry grass. USFS Approved Spark Arrestor Your Polaris ATV has a muffler that was tested and approved in accordance with the USFS Forest Service Standard 5100-1A. Exhaust Emission Control System The exhaust emission control system is composed of efficient carburetor settings with an optimum ignition system.

  • Page 71: Maintenance And Lubrication

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

  • Page 72: Periodic Maintenance Schedule

    20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Improperly performing the procedures marked with a in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Brake System Auxiliary Brake...
  • Page 73 1000 mi. 100 hrs. 6 months Drain deposits whenever visible Check operation daily; ap- ply Polaris dielectric grease to connector when replaced Check operation daily; ap- ply Polaris dielectric grease to socket when replaced Inspect; replace as needed Inspect monthly; change annually Check terminals;...
  • Page 74 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Improperly performing the procedures marked with a in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Carburetor float bowl Throttle Cable/ETC Switch Choke (enricher)
  • Page 75 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Rear axle " Ignition Timing Fuel system Fuel filter Radiator Cooling system hoses Spark arrestor Clutches (drive and driven) Engine mounts Brake fluid Front wheel bear- ings Idle speed Toe adjustment Headlight aim Hours/ Frequency Remarks Miles...
  • Page 76 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Date Dealer or Person Remarks...
  • Page 77 - NOTES -...

  • Page 78: Lubrication Guide

    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 Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging.
  • Page 79 MAINTENANCE AND LUBRICATION Lubrication Guide (Fig. 1) (Fig. 1) (Fig. 2) (Fig. 2) (Fig. 3) (Fig. 4) (Fig. 6) (Fig. 5)

  • Page 80: Premium 4 Synthetic Lubricant

    +49° C.) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it’s 0W-40.

  • Page 81: Oil Check

    MAINTENANCE AND LUBRICATION Oil Check The oil dipstick and fill tube (1) are located on the left side of the vehicle. 1. Position the ATV on a level surface. 2. Start the engine and let it idle for 20-30 seconds. 3.

  • Page 82: Oil And Filter Change

    MAINTENANCE AND LUBRICATION Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent service.
  • Page 83 MAINTENANCE AND LUBRICATION Oil Change (400/500) 7. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 8. Lubricate the gasket on the new filter with a film of new engine oil.
  • Page 84 MAINTENANCE AND LUBRICATION Oil Change (600/700) 1. Place the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area around the drain plug. 4. Place a drain pan beneath engine crankcase and remove the drain plug.

  • Page 85: Oil Change

    The transmission oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. We recommend the use of Polaris Premium Synthetic Gearcase Lubricant. See page 121 for the part numbers of Polaris products.
  • Page 86 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. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). See page 121 for the part numbers of Polaris products.
  • Page 87 The transmission oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. We recommend the use of Polaris Premium Synthetic Gearcase Lubricant. See page 121 for the part numbers of Polaris products.
  • Page 88 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. We recommend the use of Polaris Premium Hub Drive Fluid. See page 121 for the part numbers of Polaris products. Oil Check 1.
  • Page 89 The rear gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Rear gearcase oil should be changed annually. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 121 for the part numbers of Polaris products.

  • Page 90: Engine Cooling System

    50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 121 for the part numbers of Polaris products. 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...

  • Page 91: Radiator Coolant Level

    NOTE: To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water 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.

  • Page 92: Front Brake

    Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid (see page 121). 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel.

  • Page 93: Rear Brake

    MAINTENANCE AND LUBRICATION Rear Brake The rear brake is a hydraulic disc brake and is activated by the same lever that 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.

  • Page 94: Toe Alignment

    NOTE: If you discover improper alignment, see your Polaris dealer for service. Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. WARNING...

  • Page 95: Side Panel Removal

    MAINTENANCE AND LUBRICATION Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs.

  • Page 96: Wheel Removal

    MAINTENANCE AND LUBRICATION Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the owner’s manual.

  • Page 97: Wheel Installation

    5. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service.

  • Page 98: Filter Systems

    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the air box cover clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2).

  • Page 99: Headlight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 100: High Beam Adjustment

    MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a level surface with the headlight approximately 25 ft.

  • Page 101: Headlight Housing Replacement

    MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of 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.
  • Page 102 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) in a clockwise direction. 2. Pull the harness assembly out from the headlight assembly. 3. Remove the headlamp and replace with a new headlamp.

  • Page 103: Spark Plugs

    S Spark plug torque is 18 ft. lbs. (24 Nm). Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.

  • Page 104: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

  • Page 105: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.

  • Page 106: Pvt System

    MAINTENANCE AND LUBRICATION PVT System 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.

  • Page 107: Pvt Drying

    Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation.
  • Page 108 MAINTENANCE AND LUBRICATION Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. Keep the conventional battery terminals and connections 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.

  • Page 109: Battery Removal

    MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect the hold-down strap holding the battery in position, and remove battery cover. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5.

  • Page 110: Battery Storage

    MAINTENANCE AND LUBRICATION Battery Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take the battery to your dealer for testing and recharging.
  • Page 111 MAINTENANCE AND LUBRICATION Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery. NOTE: When using an automatic charger, refer to the charger manufacturer’s instructions for recharging.

  • Page 112: Cleaning And Storage

    Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

  • Page 113: Fluid Levels

    Use dish soap type cleaners only. High pressure washers may force water past seals. Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15-20 minutes of operation...

  • Page 114: Storage Tips

    6. Turn the engine over several times to ensure coverage of piston rings, cylinder walls and crankshaft bearings. 7. If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. To eliminate any fuel remaining in the carburetor, run the engine until it stops.

  • Page 115: Transporting The Atv

    Set the tire pressure and safely support the ATV with the tires 1-2” off the ground. Be sure the storage area is well ventilated, and 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.

  • Page 116: Camber And Caster

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference.

  • Page 117: Carburetor/Idle Rpm

    +40 degrees F. (4 degrees C.) NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area. ADJUSTMENTS...

  • Page 118: Throttle Cable Freeplay

    ADJUSTMENTS Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever.

  • Page 119: Troubleshooting

    10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Contact your Polaris dealer for inspection of clutch com- ponents. fuel lines, or carburetor. Contact your dealer for service.
  • Page 120 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start...
  • Page 121 TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...

  • Page 122: Engine Overheating

    Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.5 VDC...

  • Page 123: Polaris Products

    2871312 Grease Gun Kit 2871329 Dielectric Grease (Nyogelt) Coolant 2871323 60/40 Coolant (Gallon) 2871534 60/40 Coolant (Quart) Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870990 DOT3 Brake Fluid 2872893 Engine Degreaser POLARIS PRODUCTS...

  • Page 124: Specifications

    Q-0 (829) 4GAC33-3 2 3/4 turn (taper 12.5°) 250 w 9:2 Full Stroke BST 34mm Digital CDI 30° +/- - 2° @ 5000 RPM NGK BKR5E / 0.9 mm / .036 in Dry Sump Dual sensing, automatic PVT (Polaris Variable Transmission)
  • Page 125 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - Forward Drive Ratio - Front Drive Ratio - Final Tire, Front Tire, Rear Front Brake Rear Brake Auxiliary Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brakelight...
  • Page 126 SPECIFICATIONS Gross Vehicle Weight Hitch Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke...
  • Page 127 Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - Forward Drive Ratio - Front Drive Ratio - Final Tire, Front Tire, Rear Front Brake Rear Brake Auxiliary Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights...
  • Page 128 SPECIFICATIONS Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Front Rack Capacity Rear Rack 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...
  • Page 129 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 Jetting and Clutching Charts (Sportsman 600)
  • Page 130 SPECIFICATIONS Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer Towing Capacity* Front Rack Capacity Rear Rack 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...
  • Page 131 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 Jetting and Clutching Charts (Sportsman 700)

  • Page 132: Warranty

    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.
  • Page 133 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.

  • Page 134: Engine Oil

    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.
  • Page 135 In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
  • Page 136 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...

  • Page 137: Index

    Accessories ....ADJUSTMENTS ... Age Restrictions ....Air Filter Service .
  • Page 138 Parking on an Incline ... . . Periodic Maintenance Schedule POLARIS PRODUCTS ... Pre-Ride Inspection ....
  • Page 139 Improper vehicle use can result in SEVERE INJURY or DEATH. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER: Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DRUGS before or while operating this vehicle.

This manual is also suitable for:

Sportsman 400 ho 2004Sportsman 500 ho 2004Sportsman 600 ho 2004Sportsman 700 ho 2004

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