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Polaris MV700 Owner's Manual For Maintenance And Safety

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  • Page 3 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 4 S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
  • Page 5 Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 6: Table Of Contents

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

  • Page 8: Vehicle Identification Numbers

    VEHICLE IDENTIFICATION NUMBERS Record your vehicle’s identification numbers in the spaces provided. Vehicle Model Number: Frame VIN (1): Engine Serial Number (2):...

  • Page 9: Safety

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

  • Page 10: Operator Safety

    Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. 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 11 S Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCourse S Never allow anyone under 16 years of age to operate this ATV.
  • Page 12 Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

  • Page 13: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 14 ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV.
  • Page 15 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 16 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 17 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 18 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. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating.
  • Page 19 SAFETY Operator Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury.
  • Page 20 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 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25_. Practice on smaller hills before attempting large hills.
  • Page 22 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 23 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...
  • Page 24 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 25 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 26 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 27 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.
  • Page 28 SAFETY Operator Safety WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills.

  • Page 29: Safe Riding Gear

    2. Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V- -8, Z87.1, or CE.

  • Page 30: Controls

    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 31: Throttle Lever

    Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the...

  • Page 32: Brake Lever

    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. To operate the lights, the ignition switch lever must be in the ON position and the stop switch must be in the RUN position.

  • Page 33: Master Cylinder

    When checking the fluid level, the ATV must be on level ground with the handlebars straight. If the fluid level is low add DOT 4 brake fluid only. See page 111 for the part numbers of Polaris products. WARNING After opening a bottle of brake fluid, always discard any unused portion.

  • Page 34: Parking Brake

    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. Locking the Parking Brake 1. Place the transmission in PARK.

  • Page 35: Auxiliary Brake

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

  • Page 36: Fuel Requirements

    Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 47 for correct choke and throttle settings during starting. Fuel Requirements Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Fuel Valve The fuel valve (1) is located on the left side panel.

  • Page 37: Belt Life

    CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift into HIGH or PARK, apply the auxiliary brake to activate the high/park lock-out mechanism.

  • Page 38: Features

    The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting.

  • Page 39: Run-Flat Tires

    If you must operate the vehicle with flat tires, remove all cargo and towed loads from the ATV, and do not exceed 50 miles (80 km) at 25 MPH (40 km/h). Have the tire(s) inspected by an authorized Polaris dealer as soon as possible and before further use. Winches...
  • Page 40 All Wheel Drive (AWD) System 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, the ATV is in 2-wheel drive at all times.

  • Page 41: 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 or kilometers 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 42: Rider Information Center

    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 cluster’s electrical system. If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - This...
  • Page 43 FEATURES Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 27. NOTE: The transmission cannot be in reverse when using this feature.

  • Page 44: Diagnostic Mode

    FEATURES Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the ignition switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode.
  • Page 45 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).
  • Page 46 Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference.

  • Page 47: Operation

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

  • Page 48: Break-In Period

    Break-In Period The break- -in period for your new Polaris ATV is 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 49: Pre-Ride Inspection

    Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear helmet, goggles, protective...

  • Page 50: Starting The Engine

    Starting the 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. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.

  • Page 51: Cold Weather Operation

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

  • Page 52: Hauling Cargo

    OPERATION Hauling Cargo Do not exceed the weight capacities specified for the vehicle. 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. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.
  • Page 53 OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can 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 54: Driving Procedures

    Driving Procedures 1. Wear protective riding gear. See page 26. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.

  • Page 55: Making Turns

    OPERATION Making Turns Your ATV is equipped with a rear axle that 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 56: Driving On Slippery Surfaces

    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. Engage AWD before wheels begin to lose traction. 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause...

  • Page 57: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Shift your weight uphill. 5. Proceed at a steady rate of speed and throttle opening. 6.
  • Page 58 Driving on a Hillside (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 dangerous and should be avoided if at all possible.

  • Page 59: Driving Downhill

    OPERATION Driving Downhill WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death. Slow down. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control and serious injury or death. Apply the brakes gradually.

  • Page 60: Turning Around On A Hill

    Turning Around on a Hill If the vehicle stalls while climbing a hill, never back down the hill! Use the K-turn to turn around. 8 ft. (2.4 m) 1. Stop the vehicle and lock the parking brake while keeping body weight uphill.

  • Page 61: Driving Through Water

    OPERATION 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. Choose a crossing where both banks have gradual inclines.

  • Page 62: Driving Over Obstacles

    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 63: Driving In Reverse

    Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Your Polaris ATV is equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle.

  • Page 64: Parking On An Incline

    OPERATION Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5.

  • Page 65: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 66: Maintenance

    Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are important for proper vehicle operation.

  • Page 67: Periodic Maintenance Chart

    Perform these procedures more frequently for vehicles subjected to " severe use. Emission Control System Service (California) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a result in component failure and lead to serious injury or death.

  • Page 68: Periodic Maintenance Chart

    Engine breather 25 H " filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride Pre-Ride...
  • Page 69 " Exhaust muffler/ 100 H pipe Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 50 H 500 (800)
  • Page 70 Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 12 M 1000 (1600) Inspect; replace as needed...

  • Page 71: Lubrication Guide

    Rear Gearcase Oil Premium ATV Angle Drive Fluid General Lubrication Polaris Premium All Season Grease Front Prop Shaft Yoke Polaris Premium U- -Joint Lube (Fig. 1) Lube Add to proper level on dip- stick. Maintain level between fill lines. See page 30.

  • Page 72: Premium 4 Synthetic Lubricant

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

  • Page 73: Oil Check

    MAINTENANCE Oil Check The dipstick/oil fill (1) is located on the engine on the left side of the ATV. Do not start the engine before the oil check. NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase.

  • Page 74: Oil And Filter Change

    Oil and Filter Change Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. Always install a new filter when changing the oil. 1. Position the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine.

  • Page 75: Gearcase Specification Chart

    MAINTENANCE Gearcase Specification Chart Gearcase Lubricant Main Premium Gearcase (Transmission) Synthetic Gearcase Demand Drive Demand Unit (Front Gearcase) Premium Rear Premium Gearcase ATV Angle Drive Fluid Capacity 15.2 oz. (450 ml) Lube 9 oz. Drive LT (265 ml) Fluid 10 oz. (300 ml) Fill Plug Drain...

  • Page 76: Fluid Change

    Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 111 for the part numbers of Polaris products. The fill plug (1) is located on the right side of the demand drive unit.

  • Page 77: Transmission Oil

    Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 111 for the part numbers of Polaris products. The transmission oil fill plug (2) is located on the right side of the ATV behind the footwell. The transmission drain plug (3), is located on the bottom left-hand side of the gearcase.

  • Page 78: Rear Gearcase Oil

    Maintain the oil level (2) even with the bottom of the side fill hole. Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 111 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface.

  • Page 79: Engine Cooling System

    Engine Cooling System To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.

  • Page 80: Radiator Coolant Level

    Engine Cooling System Radiator Coolant Level 1. Remove the bolts securing the front rack. See illustration. 2. Remove the rack. 3. Remove the pressure cap (1). 4. Using a funnel, slowly add coolant through the radiator filler neck. 5. Reinstall the pressure cap. 6.

  • Page 81: Coolant Level

    MAINTENANCE 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 82. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

  • Page 82: Steering Assembly

    Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment.

  • Page 83: Brakes

    Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 4 brake fluid. Do not overfill.
  • Page 84 Brakes 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64″...

  • Page 85: Side Panel Removal

    MAINTENANCE Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 3. Pull the panel downward and rearward to remove it from the ATV. 4.

  • Page 86: Wheel Removal

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Wheel Removal 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake.

  • Page 87: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the transmission in PARK. 2. Lock the parking brake.

  • Page 88: Air Filter Service

    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). Wash the pre-filter in soapy water, then rinse and let dry.

  • Page 89: Headlight Lamp Replacement

    MAINTENANCE 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 90: High Beam Adjustment

    Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.

  • Page 91: Low Beam Adjustment

    MAINTENANCE Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward. 1. Loosen the headlamp mounting bolt (1). 2. Tilt the headlamp upward or downward. 3. Tighten the bolt. Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod.
  • Page 92 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 install the new headlamp. 4. Install the new headlamp and harness assembly into the headlight assembly.

  • Page 93: Spark Plugs

    Spark Plug Recommendations CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 112 for the recommended spark plug type and gap for your vehicle. Spark Plug Torque Specification...
  • Page 94 Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be flaky and white.

  • Page 95: Vehicle Immersion

    MAINTENANCE 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 96: Recoil Housing

    Recoil Housing Always drain the recoil housing (1) after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. NOTE: Make sure the housing is completely dry before reinstalling the drain screw. NOTE: Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water.

  • Page 97: Spark Arrestor

    MAINTENANCE 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 98: Pvt System

    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 99: Pvt Drying

    Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation.
  • Page 100 Battery Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

  • Page 101: Battery Removal

    MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.

  • Page 102: Battery Installation

    Battery Battery Installation 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. Install the battery vent tube. NOTE: The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

  • Page 103: Battery Storage

    Power plug leads may need to be bent down so that the battery cover can be installed. NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left...

  • Page 104: Camber And Caster

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod.
  • Page 105 MAINTENANCE Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase...

  • Page 106: Throttle Cable Freeplay

    6. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position. Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer. MAINTENANCE...

  • Page 107: Cleaning And Storage

    Do not allow these types of products to come into contact with the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

  • Page 108: Washing The Vehicle

    NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

  • Page 109: Storage Tips

    Stabilize the Fuel 1. Fill the fuel tank. 2. Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It cleans the fuel system, the combustion chamber and the exhaust ports. It also prevents bacterial growth and promotes better starting after the storage period.

  • Page 110: Fluid Levels

    7. Treat the fuel system with Polaris Carbon Clean. See page 106. 8. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 111 Inspect and Lubricate Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Battery Storage See page 100 for storage and charging procedures.
  • Page 112 Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a ”like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 113: Transporting The Atv

    MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK and lock the parking brake. 3. Turn the fuel valve off. Make sure the fuel caps, oil cap and seat are installed securely.

  • Page 114: Polaris Products

    60/40 Coolant (qt.) Additives / Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Brake Fluid 2872893 Engine Degreaser 2871956 LOCTITE 565 Thread Sealant 2871076 Polaris Battery Tender Charger POLARIS PRODUCTS...

  • Page 115: Specifications

    Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type MV700 1900 lbs. (862 kg) 1170 lbs. (531 kg) 4.75 gal. (18 l) 4.0 gal. (15 l) 1500 lbs. (681 kg) 200 lbs. (91 kg) 400 lbs.

  • Page 116: Jetting Chart

    Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) *EBS models require no helix / spring adjustment SPECIFICATIONS MV700 Side Lever (H/L/N/R/P) 7.49/1 5.11/1 3.05/1 3.82/1 3.10/1 25 x 8 - 12 / 5 psi (34.5 KPa) 25 x 8 - 12 / 5 psi (34.5 KPa)

  • Page 117: Troubleshooting

    10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Contact your Polaris dealer for inspection of clutch com- ponents. fuel lines, or carburetor. Contact your dealer for service.
  • Page 118 Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start...
  • Page 119 Incorrect jetting Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...

  • Page 120: Engine Overheating

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

  • Page 121: Warranty

    ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.
  • Page 122 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in ma- terial 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...

  • Page 123: Engine Oil

    HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 124 How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
  • Page 125 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
  • Page 126 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.

  • Page 127: Maintenance Record

    MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 128 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 129 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS...

  • Page 130: Index

    Accessories ....Age Restrictions ....Air Filter Service .
  • Page 131 Parking on an Incline ... Periodic Maintenance Chart Polaris Products ....Pre-Ride Inspection ... . .

This manual is also suitable for:

2007 mv700

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