Polaris 2004 SPORTSMAN User manual

Owner's Manual
for Vehicle Maintenance
and Safety
Owner's Manual
for Vehicle Maintenance
and Safety
2004
2004
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.
SPORTSMAN
SPORTSMAN

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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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

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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.
Copyright 2002
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.

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WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational Vehicles
Snowmobiles
All-terrain vehicles (ATVs)
Watercraft
RANGER utility vehicles
Victory motorcycles
Polaris Professional Series Workmobilest
Utility Task Vehicles(UTVs)
Personal Task Vehicles(PTVs)
All-Surface Loaders (ASLs)
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
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.

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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.
Remove the spare key and store it in a safe place. Your key can be
duplicated only by mating a Polaris key blank with one of your
existing keys. If both keys are lost, the ignition switch must be
replaced. See your Polaris dealer.
NOTE: Record your vehicle’s ID numbers and key number (3) in the
spaces provided.
2
1
31XX
3
2
400/500
600/700
Frame VIN:
Engine Serial Number:
Vehicle Model Number:
Key Number:

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TABLE OF CONTENTS
WELCOME 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS 4. . . . . . . . . . . . . . .
TABLE OF CONTENTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEMS 68. . . . . . . . . . . . . . . . . . .
MAINTENANCE AND LUBRICATION 69. . . . . . . . . . . . . . . .
TROUBLESHOOTING 117. . . . . . . . . . . . . . . . . . . . . . . . . . . .
POLARIS PRODUCTS 121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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. The part number is printed on the decal.
7079083
1997, 2000
IF OWNER’S MANUAL IS MISSING, CONTACT
A POLARIS DEALER FOR A REPLACEMENT.
WARNING
Never operate this vehicle on HILLS steeper than 25 degrees
25°.To prevent flipover on hilly terrain, when going up or down, use
throttle and brakes gradually.
REVERSE operation can be dangerous, even at low speeds.
Steering becomes difficult. To prevent flipover, avoid sudden braking
or sharp turns.
Use OVERRIDE for reverse speed limiter with caution. To prevent loss
of control, never activate override button with open throttle.
PARKING BRAKE may relax when used for more than 5 minutes.
When parking on grades, leave shift in forward.
WARNING
Operating this vehicle if you are under
the age of 16 increases your chance
of severe injury or death.
NEVER operate this vehicle if you are
under age 16.
WARNING
7079085

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SAFETY
Safety Decals and Locations
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 kg).
Reduce speed and allow greater distance for braking when carrying
cargo. Overloading or carrying tall, off-center, or unsecured loads
will increase your risk of losing control. Loads should be centered,
carried as low as possible, and firmly secured to the racks. With
dual racks, load distribution 1/3 front 2/3 rear is best. For stability
on rough or hilly terrain, reduce speed and cargo. Do not block
headlight. Be careful if load extends over the side of the rack.
Read Owner’s Manual for more detailed loading information
WARNING
7079084
WARNING
7077920
ATTENTION
Operation of this vehicle without the air
filter element will severely damage the
engine.
Clean pre-filter element often, more
frequent cleaning required in dusty
conditions. Do not operate vehicle
without pre-filter.
Operation of this vehicle without engine
breather filter(s) can cause engine
damage. Consult owner’s manual or
dealer for details.
Factory setting:
40to 80F. at 0-3000 feet
(5to 27 C. at 0-900 meters).
7079902
Specific carburetor jetting and
adjustments are required depending
on temperature and altitude. See
your Owner’s Manual.

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SAFETY
Safety Decals and Locations
Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle with
guard removed.
Do not modify engine or clutch. Doing so can cause
part failure, possible imbalance, and excessive engine
RPM which can result in serious injury or death.
NO STEP
7078689
WARNING
DO NOT TOW FROM RACK OR BUMPER.
Vehicle damage or tipover may result causing severe injury
or death. Tow only from tow hooks or hitch.
Max Rack Loads: Front 100 lbs. (45 kg) Rear 200 lbs. (91 kg) 7170912
WARNING
DO NOT TOW FROM RACK OR BUMPER.
Vehicle damage or tipover may result causing severe injury
or death. Tow only from tow hooks or hitch.
Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg) 7170021
WARNING
Sportsman 400/500
Sportsman 600/700