Polaris Sprotsman 700 Safety And Maintenance Manual
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Polaris Sprotsman 700 Safety And Maintenance Manual

Polaris 2002 atv owner's manual
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Summary of Contents for Polaris Sprotsman 700

  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects or other reproductive harm.
  • 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 Your Owner’s Manual contains instructions for minor maintenance. Major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician. Your Polaris dealer knows your vehicle best and is interested in your complete satisfaction.

  • Page 5: Know Your Vehicle

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV Pro 500 is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Vehicle Identification Numbers Vehicle Specifications Safety ........Understanding Warnings Key Safety Issues Decals and Locations...
  • Page 7 Maintenance and Lubrication Periodic Maintenance Schedule Lubrication Recommendations Maintenance Record Cooling System Lubrication ........Filter Systems Adjustments .

  • Page 8: Vehicle Identification Numbers

    NOTE: Record your vehicle’s ID numbers in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with an existing key. NOTE: If both keys are lost, see your dealer for ignition switch replacement.

  • Page 9: Vehicle Specifications

    Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output...

  • Page 10: Clutching And Jetting Charts

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

  • Page 11: Safety

    Understanding Warnings The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

  • Page 12: Key Safety Issues

    All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.
  • Page 13 S Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. S Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident. SAFETY...
  • Page 14 SAFETY Key Safety Issues S Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill.
  • Page 15 Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications to the vehicle for these purposes.

  • Page 16: Decals And Locations

    Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.

  • Page 17: Safety Decals And Locations

    SAFETY Safety Decals and Locations WARNING IF OWNER’S MANUAL IS MISSING, CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT. E1997, 2000 7079083...
  • Page 18 SAFETY Safety Decals and Locations...
  • Page 19 Safety Decals and Locations F Never operate this ATV on HILLS steeper than 25 degrees To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually. F REVERSE operation can be dangerous even at low speeds. Steering becomes difficult.
  • Page 20 SAFETY Safety Decals and Locations...
  • Page 21 SAFETY Safety Decals and Locations (on rear of seat) WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS.
  • Page 22 SAFETY Safety Decals and Locations Operation of this vehicle without the air filter element will severely damage the engine. Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter. Operation of this vehicle without engine breather filter(s) can cause engine damage.
  • Page 23 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 7078261 SAFETY 7170021 MANUFACTURED BY: POLARIS IND INC. DATE: VIN: 7078472 PRINTED IN U.S.A.

  • Page 24: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding.

  • Page 25: Operator Safety

    ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris ATV. WARNING WARNING SAFETY...
  • Page 26 SAFETY Operator Safety POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 27 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
  • Page 28 SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
  • Page 29 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident.
  • Page 30 SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
  • Page 31 SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
  • Page 32 SAFETY Operator Safety POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 33 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
  • Page 34 SAFETY Operator Safety POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
  • Page 35 Operator Safety POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner’s Manual. See page 72 . Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 36 SAFETY Operator Safety POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner’s Manual. See pages 74 through 77. Always check the terrain carefully before you start up any hill.
  • Page 37 SAFETY Operator Safety WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 76. NOTE: A special technique is required when braking as you go downhill.
  • Page 38 SAFETY Operator Safety POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground.
  • Page 39 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 40 SAFETY Operator Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 41 Operator Safety POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (pg 78), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and...
  • Page 42 Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer.
  • Page 43 Operator Safety POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.
  • Page 44 SAFETY Operator Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 45 Operator Safety After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage. Safe operation of this rider active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death.

  • Page 46: Features And Controls

    CONTROLS AND FEATURES Controls Engine Electrical Switches Activating the override button while throttle is open can cause loss of control resulting in severe injury or death. 1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system.

  • Page 47: Throttle Lever

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

  • Page 48: Controls And Features

    CONTROLS AND FEATURES Controls Brakes The front and rear brakes are applied by squeezing the left side brake lever toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only. Always test brake lever travel and reservoir fluid level before riding.

  • Page 49: Front And Rear Brakes

    Controls The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms. Front and Rear Brakes The brake fluid in the master cylinder, which is located on the...

  • Page 50: Parking Brake

    CONTROLS AND FEATURES Controls Parking Brake Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the parking brake is left on while the ATV is operated. Setting the Parking Brake 1.

  • Page 51: Foot Brake

    Your Polaris ATV has a foot brake (1) provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot.

  • Page 52: Fuel System

    “on” position after refueling machine. Fuel Filter The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

  • Page 53: Fuel Safety

    Controls 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 54 CONTROLS AND FEATURES Controls Automatic Transmission Gear Selector The transmission gear selector is located on0 the right side of the vehicle directly above and forward of the engine and has five positions: high, low, neutral; reverse, and park. To shift into “High” or “Park”, you must first depress the foot brake to activate the High/Park lock out mechanism.

  • Page 55: Oil Pressure Switch

    Important Safeguards S Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless additional power is required for vehicle movement. S Avoid turning at sharp angles in reverse. S Avoid backing on steep inclines. Light Switches and Indicator Lights This ATV is not equipped with highway approved lighting.

  • Page 56: Features

    CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) system which is activated by a switch (1) on the right handlebar. When the switch is “off”...

  • Page 57: Disengaging Wheel Hubs

    CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Engage the All Wheel Drive switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the All Wheel Drive switch on.

  • Page 58: Instrument Cluster

    CONTROLS AND FEATURES Features Instrument Cluster Your Sportsman 700 is equipped with an instrument cluster which senses vehicle speed from the right hand front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed at approximately 7 to 9 mph.

  • Page 59: Rider Information Center

    Features Rider Information Center The rider information center is located in the lower portion of the instrument cluster. Gear Indicator - As the shift lever is moved, this will indicate the gear the machine is in: H = High Range L = Low Range N = Neutral R = Reverse...
  • Page 60 CONTROLS AND FEATURES Features Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button which is found on the LH handlebar is also the “mode button”.
  • Page 61 CONTROLS AND FEATURES Features Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and their dealer with a convenient way to schedule routine maintenance. When your vehicle leaves the factory, this feature is turned “OFF”.
  • Page 62 CONTROLS AND FEATURES Features Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Your dealer is fully equipped with the knowledge and special tools required to keep your machine running. Please return your ATV to your dealer for all major repairs. To enter the diagnostics mode: 1.

  • Page 63: Auxiliary Power Outlet

    Auxiliary Power Outlet Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights and is located on the front headlight pod. Accessory outlets are available for all models. Contact your Polaris dealer for more information.

  • Page 64: Operation

    OPERATION Pre Ride Inspection You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is in proper working order each time you ride.

  • Page 65: Vehicle 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 tanks full of gasoline. No single action on your part is as important as a proper break in period.

  • Page 66: Starting The Engine

    OPERATION Starting the Engine Procedure for Starting a Cold Engine Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. You must allow your vehicle adequate warm up time before operating or engine damage could result.

  • Page 67: Cold Weather Operation

    Then push the choke all the way Cold Weather Operation Polaris offers an engine heater kit for cold operation. If you use your ATV all year round, it is important to check your oil level frequently. A rising oil level could indicate the accumulation of water in the bottom of the oil tank.

  • Page 68: Carrying Loads

    OPERATION Carrying Loads Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
  • Page 69 Carrying Loads Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death. 2/3 of Load on Rear Rack Important Safeguards...
  • Page 70 OPERATION Carrying Loads LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable oper- ating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

  • Page 71: Noise Emission Control System

    S Be especially careful when traveling through tall grass. The poten- tial for fire exists. USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. NOISE EMISSION CONTROL...

  • Page 72: Riding

    RIDING Pre Ride Inspection You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is in proper working order each time you ride.

  • Page 73: Safe Riding Tips

    Safe Riding Tips Riding Position 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 74: Making Turns

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

  • Page 75: Riding On Slippery Surfaces

    Safe Riding Tips Riding on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special atten- tion must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2.

  • Page 76: Traveling Uphill

    RIDING Safe Riding Tips Traveling Uphill Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death. Whenever traveling uphill always travel straight uphill and: 1.
  • Page 77 Safe Riding Tips Sidehilling Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests.

  • Page 78: Traveling Downhill

    RIDING Safe Riding Tips Traveling Downhill Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the foot brake and its use in the event loss of normal service brakes occurs.

  • Page 79: Turning Around On A Hill

    Safe Riding Tips Turning Around on a Hill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1.

  • Page 80: Crossing Streams

    RIDING Safe Riding Tips Crossing Streams Your Polaris ATV can operate through water up to maximum recommended depths reaching the footrests. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines.

  • Page 81: Trail Obstacles

    Safe Riding Tips Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. Not all obstacles are visible.

  • Page 82: Backing Up

    6. Never activate override button while throttle is open. Loss of control may result. NOTE: Most Polaris ATVs are equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Only open the throttle enough to maintain a desired speed.

  • Page 83: Parking On An Incline

    Safe Riding Tips Parking on an Incline Whenever the Vehicle is Parked 1. Turn the engine off. 2. Place the transmission in park. 3. Set the parking brake. 4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above.

  • Page 84: Maintenance And Lubrication

    Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer. Service and adjustments are critical. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
  • Page 85 Pre-ride Pre-ride Check for free operation Pre-ride Pre-ride Drain deposits whenever visible Pre-ride Check operation daily; ap- ply Polaris dielectric grease to connector when replaced Pre-ride Pre-ride Check operation daily; ap- ply Polaris dielectric grease to socket when re- placed...
  • Page 86 Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 87 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item " Oil Filter(4-Cycle) Engine breather hose (4-cycle) Carburetor Float Bowl Throttle Cable/ETC Switch Choke (Enricher) Cable Coolant strength/ pressure test system Drive belt " Steering " Front Suspension " Rear Suspension Spark Plug "...
  • Page 88 Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 89 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Engine Mounts Valve Clearance Brake fluid Front wheel bearings Idle Speed Toe adjustment Headlight Aim Hours or When Remarks Miles 100 hrs Inspect months 100 hrs Inspect/Adjust months 200 hrs Change every two years months 300 hrs Inspect, replace if neces-...

  • Page 90: Lubrication Recommendations

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Item Lube Rec (1)Engine Oil Polaris Premium 4 Synthet- ic 0W40 (2) Brake DOT 3 Fluid Only (3) Transmis- Polaris sion Oil Premium Synthetic gear case lube (4) Front Premium Gearcase Oil Hub Lube (5) Rear...
  • Page 91 MAINTENANCE AND LUBRICATION Lubrication Recommendations (4) Front Gear Case (5) Rear Gear Case Fill plug (6) Front Prop Shaft (U-Joints) (3) Transmission (plug) Fill plug (7) Propshaft Yoke...
  • Page 92 Anti-Roll Bar Grease 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 + Grease every 500 miles, or before long periods of storage or after pressure washing, or after submerging in water.
  • Page 93 MAINTENANCE AND LUBRICATION Lubrication Recommendations (11) Steering Post Bushing Upper (13) Lower Control (15) Rear Anti- Roll Bar (8) Axle Cardan Front Drive (10) Front A Arm Pivot Shaft (13) Lower Con- trol (12) Upper Control (14) Rear Wheel Hub Bearing Carrier...

  • Page 94: Maintenance Record

    MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Servicing Interval Performed First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs. Servicing Date Dealer or Person Remarks...

  • Page 95: Cooling System

    Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use.

  • Page 96: Engine Cooling System

    MAINTENANCE AND LUBRICATION Engine Cooling System Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap. Radiator Coolant Level Inspection NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair.
  • Page 97 Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use.

  • Page 98: Lubrication

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable. Oil may need to be changed more frequently if Polaris Premium 4 is not used. You will also need to follow the manufacturers recommendations for ambient temperature operation.

  • Page 99: Oil And Filter Change

    11. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn and additional 1/2 turn. 12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 13. Place gear selector in neutral and set parking brake.

  • Page 100: Transmission Lubrication

    With the ATV on a level surface, remove fill plug (1) and check the lubricant level. Use the illustration and the chart below to determine the correct fluid level. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478). Model...

  • Page 101: Front Gearcase Lubrication

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

  • Page 102: Rear Gearcase Lubrication

    MAINTENANCE AND LUBRICATION Lubrication Rear Gearcase Lubrication With the ATV on a level surface, remove the fill plug and visually inspect the lubricant level through the fill hole (1). The lubricant level should be maintained 1 5/8 in. from the top of the fill plug hole.

  • Page 103: Oil System

    MAINTENANCE AND LUBRICATION Lubrication Oil System The oil dipstick and fill tube are located on the left side of the vehicle To check the oil: 1. Set machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds.

  • Page 104: Filter Systems

    MAINTENANCE AND LUBRICATION Filter Systems Cleaning the Main Filter NOTE: It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observe the following practices. 1. Never immerse the filter in water since dirt can be transferred to the clean air side of the filter.
  • Page 105 MAINTENANCE AND LUBRICATION Filter Systems Operation of your ATV without a breather filter can cause engine damage. Breather Filter and Hose 4-Cycle Engines With Dry Sump* 1. Take the filter(1) out of the hoses. 2. Inspect filter for debris. Blow through gently in direction of arrow on filter to check for clogging.

  • Page 106: Adjustments

    MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable.
  • Page 107 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment (cont.) 2. Place stands in front of the machine, perpendicular to the rear tires. 3. Tie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine.

  • Page 108: Rear Spring Adjustment

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

  • Page 109: Handlebar Adjustment

    MAINTENANCE AND LUBRICATION Adjustments Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit.

  • Page 110: Front Brake

    Always fill the reservoir as indicated whenev- er the cover is loosened or removed to insure proper diaphragm operation. Use Polaris DOT 3 brake fluid. S Check brake system for fluid leaks.

  • Page 111: Rear Brake

    Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right floorboard. All Polaris ATVs have hydraulic brake systems. The hydraulic foot brake will not require adjustment.
  • Page 112 MAINTENANCE AND LUBRICATION Adjustments Carburetor/Engine Idle RPM Adjustment If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by running the vehicle approximately five minutes.
  • Page 113 MAINTENANCE AND LUBRICATION Adjustments Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation.

  • Page 114: Wheel Installation

    Place one drop on the lug before installing and tightening to 30 ft. lbs. NOTE: Always use Polaris thread locker (PN 2870963) or equivalent when replacing wheel nuts. Always check wheel nut tension before riding your ATV.

  • Page 115: Tire Inspection

    MAINTENANCE AND LUBRICATION Adjustments Tire Inspection When replacing a tire always use original equipment size and type. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) (1) or less.

  • Page 116: Carburetor Adjustments

    NOTE: Contact your dealer for altitude adjustments. They have the training and special tools required to perform all necessary modifications for you. Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polaris dealer to find out about the accessories available for your machine.

  • Page 117: Lights

    MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement Keep your headlights and taillights clean. Poor lighting while riding can result in an accident causing severe injury or death. Do not service while headlight is hot. Serious burns may result. Do not touch a halogen lamp with bare fingers.

  • Page 118: Headlight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement Position knob in slot and secure in locking tabs 1. Remove the three screws securing the headlight pod. 2. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod.

  • Page 119: High Beam Headlight Adjustment

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

  • Page 120: Headlight Housing Replacement

    MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Housing Replacement 1. Lift the pod lightly while depressing the tabs. 2. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 3.
  • Page 121 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lense cover and gasket and set aside for reassembly.

  • Page 122: Spark Plugs

    MAINTENANCE AND LUBRICATION Spark Plugs Refer to page 7 for the correct spark plug for your machine. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.

  • Page 123: Water Immersion

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

  • Page 124: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor When cleaning the spark arrestor, you must follow the safeguards listed below to avoid serious injury or death. Do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. Because of the increased fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.
  • Page 125 MAINTENANCE AND LUBRICATION Spark Arrestor (cont.) 4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the parking brake and block the wheels.

  • Page 126: Pvt

    Low Range Use May Reduce PVT Operating Temperatures The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases.

  • Page 127: Pvt Drying

    MAINTENANCE AND LUBRICATION PVT System On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH, due to the system’s dependence on engine speed.

  • Page 128: Low Range

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

  • Page 129: Battery

    MAINTENANCE AND LUBRICATION Battery Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could result causing serious injury or death. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

  • Page 130: Battery Removal

    MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Remove the strap securing the battery. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. Lift the battery out of the ATV, being careful not to tip it sideways and spill electrolyte.
  • Page 131 MAINTENANCE AND LUBRICATION Battery 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion.

  • Page 132: Side Panel Removal

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

  • Page 133: Cleaning And Storage

    Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your a Polaris dealer for free replacement. Waxing the ATV Your ATV can be waxed with any non-abrasive automotive paste wax.

  • Page 134: Storage Tips

    High pressure washers may force water past seals. Drain the recoil housing. Stabilize Fuel - Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Fill the fuel tank. Follow instructions on the container for recommended amount. Carbon clean will also reduce the possibility of bacterial growth in the fuel system.
  • Page 135 Charge the battery at 1.4 amps or less until specific gravity of each cell is 1.265 or greater. Store the battery in a cool, dry, place. Charge can be maintained easily by using Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.

  • Page 136: Tool Kit

    MAINTENANCE AND LUBRICATION Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn off the engine and remove the key. It may be lost if not removed. 2. Turn the fuel valve to off. 3.

  • Page 137: Troubleshooting

    Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Loading the ATV into a pick- up or tall trailer when in high range. Starting out going up a steep incline. Driving at low RPM or low ground speed (at approxi- mately 3-7 MPH).

  • Page 138: Troubleshooting

    For inspection of clutch components, please contact your Polaris dealer. Fouled plugs, foreign material or old fuel in gas tank, fuel lines, or carbure- tor. Contact your dealer for further ser- vice information.
  • Page 139 The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE TURNS OVER BUT FAILS TO START...
  • Page 140 TROUBLESHOOTING ENGINE STOPS OR LOSES POWER No Fuel Turn Fuel Valve to “Res” Fuel Vent Line Kinked or Plugged Water in Fuel Overuse of Spark Plug Fouled Air Filter Clogged Reverse Speed Limiter Malfunction Electronic Throttle Control Malfunction Contact Your Dealer Choke Engine...
  • Page 141 - NOTES -...

  • Page 142: Wiring Diagram

    WIRING DIAGRAM...

  • Page 143: Warranty

    This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc.
  • Page 144 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 145 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 146 INDEX Accessories ....Adjustments ....Age Restrictions ....Air Filter .
  • Page 147 Rider Information Center RIDING ....Riding on Slippery Surfaces Riding Position ....Safe Riding Gear .

This manual is also suitable for:

2002 sportsman 700

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