Polaris 2004 SPORTSMAN Owner's Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. 2004 SPORTSMAN
  6. Owner's manual

Polaris 2004 SPORTSMAN Owner's Manual

Owner's manual for vehicle maintenance and safety
Hide thumbs Also See for 2004 SPORTSMAN:
Table of Contents

Advertisement

Quick Links

2004
2004
SPORTSMAN
SPORTSMAN
Owner's Manual
Owner's Manual
for Vehicle Maintenance
for Vehicle Maintenance
and Safety
and Safety
Read this manual carefully. It contains important safety information.
Operation is prohibited for those under 16 years of age.
This is an adult vehicle only.

Advertisement

Table of Contents
loading

Related Manuals for Polaris 2004 SPORTSMAN

Summary of Contents for Polaris 2004 SPORTSMAN

  • Page 1 2004 2004 SPORTSMAN SPORTSMAN Owner's Manual Owner's Manual for Vehicle Maintenance for Vehicle Maintenance and Safety and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
  • 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! Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out... www.polarisindustries.com/owner...
  • 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

    We also take great pride in our Parts Apparel and Accessories (PAA) products, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door! Polaris, Polaris The Way Out, and Workmobiles are registered trademarks of Polaris Industries Inc.

  • Page 6: Vehicle Identification Numbers

    VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS WELCOME ........VEHICLE IDENTIFICATION NUMBERS .

  • Page 8: Safety

    SAFETY Safety Decals and Locations 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 Safety Decals and Locations ATTENTION S Operation of this vehicle without the air S Specific carburetor jetting and filter element will severely damage the adjustments are required depending engine. on temperature and altitude. See S Clean pre-filter element often, more your Owner’s Manual.
  • Page 10 SAFETY Safety Decals and Locations WARNING Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.
  • Page 11 SAFETY Safety Decals and Locations WARNING ALL WHEEL MANUFACTURED Pushing reverse DRIVE BY: POLARIS IND INC. override button SWITCH may cause sudden in- DATE: creases in pow- Do not push switch to er and traction if engage AWD if the rear too much VIN: wheels are spinning.

  • 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

    SAFETY Operator Safety WARNING 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.
  • 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 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described.
  • 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. S Always follow proper procedures for climbing hills.

  • Page 17: Equipment Modifications

    SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test the brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operat- ing in reverse.
  • Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris.
  • 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 WARNING 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 WARNING 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 SAFETY Operator Safety WARNING 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 WARNING 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.
  • Page 25 SAFETY Operator Safety WARNING 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 WARNING 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 WARNING 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.
  • 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 WARNING 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 WARNING 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 SAFETY Operator Safety WARNING 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 WARNING 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...
  • Page 36 SAFETY Operator Safety WARNING 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.
  • Page 37 SAFETY Operator Safety WARNING 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 WARNING 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

    CONTROLS WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise.

  • 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

    CONTROLS Master Cylinder The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder.

  • Page 42: Parking Brake

    CONTROLS Parking Brake WARNING 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

    CONTROLS Auxiliary Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

  • 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 CONTROLS 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, Demand 4 Drive (AWD) system, which is activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times.

  • Page 47: Instrument Cluster

    FEATURES 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

    FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electrical system.
  • 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 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 WARNING 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

    OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two 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 WARNING 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

    OPERATION Starting the Engine Starting a Cold Engine WARNING 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

    OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in neutral (or PARK if equipped).

  • 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 WARNING 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

    OPERATION 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

    OPERATION 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 25_ Maximum 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 OPERATION Driving Safely Sidehilling WARNING 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

    OPERATION Driving Safely Turning Around on a Hill WARNING 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

    OPERATION 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. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 68: Driving In Reverse

    OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing.

  • 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

    EMISSION CONTROL SYSTEMS Noise Emission Control System TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or...

  • Page 71: Maintenance And Lubrication

    MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance schedule. Use the instrument cluster’s programmable service interval mode to help determine when maintenance service is due.

  • Page 72: Periodic Maintenance Schedule

    MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. WARNING Improperly performing the procedures marked with a could result...
  • Page 73 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Frequency Remarks Miles " Air box sediment Pre-Ride Pre-Ride Drain deposits whenever tube visible Headlamp Pre-Ride Pre-Ride Check operation daily; ap- ply Polaris dielectric grease to connector when replaced Tail lamp/brake Pre-Ride Pre-Ride Check operation daily;...
  • Page 74 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Frequency Remarks Miles Carburetor float 50 hrs.
  • Page 75 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Frequency Remarks Miles " Rear axle 50 hrs. 6 months Inspect bearings; lube Ignition Timing 100 hrs. 12 months Inspect; adjust as needed Fuel system 12 months Check for leaks at tank hours cap, lines, fuel valve, filter, pump and carburetor;...
  • Page 76 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person 10 hrs. 20 hrs. 50 hrs. 100 hrs.
  • Page 77 - NOTES -...

  • Page 78: Lubrication Guide

    MAINTENANCE AND LUBRICATION Lubrication Guide NOTE: Hours in the frequency column are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Guide Key "...
  • 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

    MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. NOTE: See page 121 for the part numbers of Polaris products.

  • 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

    MAINTENANCE AND LUBRICATION Transmission Oil (400/500) 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 MAINTENANCE AND LUBRICATION Front Gearcase Oil (400/500) 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 MAINTENANCE AND LUBRICATION Transmission Oil (600/700) 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 MAINTENANCE AND LUBRICATION Front Gearcase Oil (600/700) 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.
  • Page 89 MAINTENANCE AND LUBRICATION Rear Gearcase Oil (600/700) 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

    MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 93. The fluid level must be maintained between the minimum and maximum marks on the bottle (when the fluid is cool).

  • Page 91: Radiator Coolant Level

    MAINTENANCE AND LUBRICATION Engine Cooling System WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair.

  • Page 92: Front Brake

    MAINTENANCE AND LUBRICATION Front Brake WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.

  • 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

    MAINTENANCE AND LUBRICATION Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″...

  • 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. Step 2 2. Grasp the rear of the side panel near the rear cab.

  • Page 96: Wheel Removal

    MAINTENANCE AND LUBRICATION WARNING 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

    MAINTENANCE AND LUBRICATION Wheel Installation 1. Place the transmission in gear (or in PARK if equipped) and lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.

  • 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. WARNING 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

    MAINTENANCE AND LUBRICATION Spark Plugs S Use BKR5E spark plugs for the Sportsman 400 and 500. S Use RC7YC spark plugs for the Sportsman 600 and 700. S Proper electrode gap is .035″ (.90 mm). S Spark plug torque is 18 ft. lbs. (24 Nm). CAUTION Using non-recommended spark plugs can result in serious engine damage.

  • Page 104: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION 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 WARNING 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

    MAINTENANCE AND LUBRICATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced.
  • 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

    MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your ATV. See your Polaris dealer. Cleaning and Storage See page 121 for the part numbers of Polaris products.

  • Page 113: Storage Tips

    MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime.
  • Page 114 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Fog the Engine 1. Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.

  • Page 115: Transporting The Atv

    MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Maintenance (Conventional) Remove the battery and add distilled water to the proper level. Do not use tap water, which may contain minerals that reduce battery life. Apply dielectric grease to the terminal bolts and terminals. Charge the battery at 1.4 amps or less until the specific gravity of each cell is 1.265 or greater.

  • Page 116: Camber And Caster

    ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer.

  • Page 117: Carburetor/Idle Rpm

    ADJUSTMENTS Carburetor/Idle RPM If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Warm up the engine by running the vehicle for approximately five minutes. 2. Place the transmission in gear with the parking brake applied.

  • 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

    TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a Shift transmission to low range during loading of the ATV pickup or tall trailer in to prevent belt burning. high range. Starting out going up a When starting out on an incline, use low range or dis- steep incline.
  • 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 Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten...
  • Page 121 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer...

  • Page 122: Engine Overheating

    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires...

  • Page 123: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) 2871844 Engine Oil (gal.) Premium 4 Synthetic 0W-40 (4-Cycle) Gearcase / Transmission Lubricants 2871477 Premium Synthetic Gearcase Lubricant (1 gal.) 2871478 Premium Synthetic Gearcase Lubricant (12 oz.

  • Page 124: Specifications

    SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight 1200 lbs./544 kg Towing Capacity 1225 lbs./556 kg Hitch Tongue Capacity 120 lbs./54 kg (Rear rack weight and tongue weight not to exceed 180 lbs./81.6 kg) Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Overall Length 81 in./205.7 cm...
  • Page 125 SPECIFICATIONS SPORTSMAN 400 Shift Type Side Lever (High, Low, Neutral, Reverse) Gear Reduction - Low 8.27/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - Forward 3.34/1 Drive Ratio - Front Drive Ratio - Final 3.16:1 Tire, Front 25 x 8 - 12 (5 psi) Tire, Rear 25 x 11 - 12 (5 psi) Front Brake...
  • Page 126 SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight 1200 lbs./544 kg Towing Capacity 1225 lbs./556 kg Hitch Tongue Capacity 120 lbs./54 kg (Rear rack weight and tongue weight not to exceed 180 lbs./81.6 kg) Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Overall Length 81 in./205.7 cm...
  • Page 127 SPECIFICATIONS SPORTSMAN 500 Driving System Type Shift Type Side Lever (High, Low, Neutral, Reverse) Gear Reduction - Low 8.27/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - Forward 3.34/1 Drive Ratio - Front Drive Ratio - Final 3.16:1 Tire, Front 25 x 8 - 12 (5 psi) Tire, Rear 25 x 11 - 12 (5 psi)
  • Page 128 SPECIFICATIONS SPORTSMAN 600 Gross Vehicle Weight 1240 lbs./563 kg Fuel Capacity 4.75 gal./18 l Towing Capacity 1500 lbs./681 kg Hitch Tongue Capacity 150 lbs./68.1 kg (Rear rack capacity and tongue weight not to exceed 200 lbs./90.7 kg) Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.8 kg...
  • Page 129 SPECIFICATIONS SPORTSMAN 600 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 7.5/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 3.09/1 Drive Ratio - Front: 3.82/1 Drive Ratio - Final 3.10/1 Tire Size - Front 25 x 8 - 12 Tire Size - Rear 25 x 11 - 12...
  • Page 130 SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight 1240 lbs./563 kg Fuel Capacity 4.75 gal./18 l Towing Capacity 1500 lbs./681 kg Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.7 kg Hitch Tongue Capacity 150 lbs./68.1 kg (Rear rack capacity and tongue weight not to exceed 200 lbs./90.8 kg) Overall Length 81 in./205.7 cm...
  • Page 131 SPECIFICATIONS SPORTSMAN 700 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 7.5/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 2.89/1 Drive Ratio - Front: 3.82/1 Drive Ratio - Final 3.10/1 Tire Size - Front 25 x 8 - 12 Tire Size - Rear 25 x 11 - 12...

  • Page 132: Warranty

    WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.
  • Page 133 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured,...
  • Page 134 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
  • Page 135 INDEX Accessories ....Electrical Switches ....ADJUSTMENTS .
  • Page 136 INDEX Main Switch ....Sidehilling ..... MAINTENANCE Spark Arrestor .
  • Page 137 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER CARRY NEVER USE NEVER USE ALWAYS USE PASSENGERS AN APPROVED ON PUBLIC WITH DRUGS ROADS OR ALCOHOL HELMET AND PROTECTIVE GEAR NEVER: Operate without proper training or instruction. Operate on public roads.

This manual is also suitable for:

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

Table of Contents