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WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER CARRY ALWAYS USE NEVER USE NEVER USE ON PUBLIC PASSENGERS WITH DRUGS AN APPROVED HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER: Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DRUGS before or while operating this vehicle. Carry Passengers. ALWAYS: Avoid paved surfaces, which
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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.
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Copyright2004PolarisSalesInc.Allinformationcontainedwithinthispublicationis basedonthelatestproductinformationatthetimeofpublication. Duetoconstant improvementsinthedesignandqualityofproductioncomponents,someminor discrepanciesmayresultbetweentheactualvehicleandtheinformationpresentedinthis publication. Depictionsand/orproceduresinthispublicationareintendedforreference useonly.Noliabilitycanbeacceptedforomissionsorinaccuracies. Anyreprintingor reuseofthedepictionsand/orprocedurescontainedwithin,
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WELCOME ThankyouforpurchasingaPolaris vehicle, andwelcometoour world-widefamilyofPolarisowners. Weproudlyproduceanexciting lineofutilityandrecreational products. PolarisRecreationalVehicles S Snowmobiles S All-terrainvehicles(ATVs) S Watercraft S RANGERutilityvehicles S Victory motorcycles WebelievePolarissetsastandardofexcellenceforall utilityand recreational vehiclesmanufacturedintheworldtoday. Manyyearsof experiencehavegoneintotheengineering, design, anddevelopment of yourPolarisvehicle, maki
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TABLEOFCONTENTS WELCOME.................................... 3 VEHICLE IDENTIFICATION NUMBERS........... 7 SAFETY ...................................... 8 CONTROLS .................................. 33 FEATURES .................................. 41 OPERATION ................................. 47 EMISSION CONTROL SYSTEMS ............... 65 MAINTENANCE AND LUBRICATION ............ 66 ADJUSTMENTS ............................. 109 POLARIS PRODUCTS........................ 113 TROUBLESHOOTING ..........
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VEHICLEIDENTIFICATIONNUMBERS RecordyourATV’s identificationnumbers andkeynumberinthe spaces provided. Removethesparekey and storeit in asafeplace. YourkeycanbeduplicatedonlybymatingaPolariskeyblankwith oneofyourexistingkeys, soifbothkeysarelost, theignitionswitch must bereplaced. 2 2 1 600/700 31XX 3 400/500 VehicleModelNumber: FrameVIN (1): EngineSerialNumber (2): Key Number (3): 7
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SAFETY SafetyDecalsandLocations Warning decals havebeen placed on theATVforyourprotection. Read and followtheinstructions ofthedecals on theATVcarefully. Ifany ofthedecals depicted in this manual differfrom thedecals on your ATV, always read and followtheinstructions ofthedecals on the ATV. Ifany decal becomesillegibleorcomesoff, contact yourPolarisdealer to purchaseareplacement. Replacement safetydecals areprovided by Polaris at no charge. Thepart numberis printed on thedecal. WARNING Improper
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SAFETY SafetyDecalsandLocations WARNING IMPROPERTIRE PRESSURE OROVERLOADINGcan cause loss of control resulting in SEVERE INJURY ORDEATH. TIRE PRESSURE INPSI(KPa): FRONT5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHTCAPACITY (Gross Vehicle Weight) INCLUDINGMACHINE, DRIVER AND CARGOIS 1200 LBS. (545 kg). Reduce speed and allow greaterdistance forbraking when carrying cargo. Overloading orcarrying tall, off-center, orunsecured loads will increase yourrisk of losing control. Loads should be centered, carried
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SAFETY SafetyDecalsandLocations WARNING WARNING S Movingparts hazardunderbelt-clutchguard.To preventserious injury,donotoperatevehicle withguardremoved. S 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. OperatingthisATVifyouareunder theageof16increasesyourchance ofsevereinjuryordeath. NEVERoperatethisATVifyouare NOSTEP 7172563 underage16. 7172559 WARNING S DONOTTOWFROMRACKORBUMPER. Vehicle
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SAFETY SafetyDecalsandLocations WARNING ALLWHEEL MANUFACTURED BY:POLARIS IND.INC. Pushing reverse DRIVE override button SWITCH DATE: may cause sudden increases VIN: Do not push switch to in power and engageAWDiftherear traction if too THISVEHICLEISANALLTERRAINVEHICLEANDISNOT wheels are spinning. much throttle is INTENDEDFORUSEONPUBLICROADS. Thismaycausesevere applied. Loss of drive shaft and clutch CEVÉHICULEESTUN VÉHICULETOUTTERRAIN QUINiEST control or forward damage. PASDESTINÉÀ ÊTREUTILISÉSUR
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SAFETY SafeRidingGear Alwayswearclothingsuitedtothetypeofriding. ATVridingrequires special protectiveclothingforcomfort andtoreducethechanceof injury. 1.Helmet Yourhelmet isthemost important piece ofprotectivegearforsaferiding. A helmet can prevent aseverehead injury. 1 Select an approved helmet that meets orexceeds yourstate’s safety standards and bears eithertheDepartment of Transportation (DOT)label, the AmericanNational Standards Institutelabel (ANSIz90.1), orthe 2 Snell Memorial Foundationl
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SAFETY Operator Safety WARNING 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. Read and understand your owner’s manual and all warnings before
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SAFETY Operator Safety Thefollowingtwopages identifysignal words andsymbols that appear inthismanual. Yoursafetyisinvolvedwhenthesewordsandsymbols areused. Becomefamiliarwiththeirmeaningsbeforereadingthe manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death. CAUTION The safety alert caution indicates a potential hazard that may re
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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 Readthismanual andall labelscarefully, andfollowtheoperating procedures described. S NeveroperateanATVwithout properinstruction. Take a training course. Beginners should receivetraining from acertified instructor. Contact an authorized Polaris ATVdealerorcall Polaris at 1-800-342-3764tofindout about thetrainin
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SAFETY Operator Safety S Always havetheATVinspected by an authorized Polaris dealerif it’s been involved in an accident. S NeveroperateonhillstoosteepfortheATVorforyourabilities. Practiceonsmallerhillsbeforeattemptinglargerhills. S Alwaysfollowproperproceduresforclimbinghills. Checktheter- raincarefullybeforeascendingahill. Neverclimbhillswithexces- sively slippery orloosesurfaces. Shift yourweight forward. Never openthethrottlesuddenlyormakesuddengearchanges. Nevergo overthetopofahill at highsp
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SAFETY Operator Safety S Wet brakesmayhavereducedstoppingability. Test thebrakesafter leavingwater. Ifnecessary, applythem lightlyseveral timestoallow friction to dry out thepads. S AlwayscheckforobstaclesorpeoplebehindtheATVbeforeoperat- ing in reverse. When it’s safeto proceed in reverse, moveslowly andavoidturningat sharpangles. S AlwaysusethesizeandtypeoftiresspecifiedforyourATV, and alwaysmaintainpropertirepressure. S Nevermodify an ATVthrough improperinstallation oruseofacces- sories. S Ne
