Polaris Sprotsman 700 Guide

WARNING
The engine exhaust from this
product contains chemicals
known to cause cancer, birth de-
fects or other reproductive harm.

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www.polarisindustries.com/owner

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WELCOME
Thank you for choosing Polaris, and welcome to our world-wide
family of Polaris enthusiasts. Polaris proudly produces an exciting line
of recreational products, including snowmobiles, all-terrain vehicles,
personal watercraft, utility vehicles, and Victory motorcycles.
We believe Polaris sets the standard of excellence for all recreational
vehicles manufactured in the world today. Many years of experience in
engineering, design, and development have gone into making your
Polaris vehicle the finest machine we’ve ever produced.
Follow the instructions and recommendations in this Owner’s Manual
for safe and enjoyable operation of your vehicle. Your Owner’s Manual
contains instructions for minor maintenance. Major repairs are covered
in the Polaris Service Manual and should be performed by a Factory
Certified MSD (Master Service Dealer) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
complete satisfaction. Return to your dealership for all of your service
needs during, and after, the warranty period.
Polaris also takes great pride in our PAA (Parts Apparel and
Accessories) which are available on our online store
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
Polaris and Polaris The Way Out are registered trademarks of Polaris
Industries Inc.
Copyright 2002
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.

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Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You
were also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
NOTE: Illustrations used in this manual are for general representation
only. Your model may differ.
WARNING
Failure to follow the warnings contained in this manual can result
in severe injury or death.
A Polaris ATV Pro 500 is not a toy and can be hazardous to
operate. This vehicle handles differently than other vehicles, such
as motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris ATV Pro 500.

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TABLE OF CONTENTS
Vehicle Identification Numbers 6. . . . . . . . . . . . . .
Vehicle Specifications 7. . . . . . . . . . . . . . . . . . . . . .
Safety 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding Warnings 9. . . . . . . . . . . . . . . . . . . . . . . . .
Key Safety Issues 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals and Locations 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Safety 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features and Controls 44. . . . . . . . . . . . . . . . . . . . .
Controls 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre Ride Inspection 62. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Break-In Period 63. . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Engine 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carrying Loads 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise Emission Control System 69. . . . . . . . . . . .
Riding 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre Ride Inspection 70. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Riding Tips 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS
Maintenance and Lubrication 82. . . . . . . . . . . . . . .
Periodic Maintenance Schedule 82. . . . . . . . . . . . . . . . . .
Lubrication Recommendations 88. . . . . . . . . . . . . . . . . . .
Maintenance Record 92. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Systems 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lights 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plugs 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Immersion 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Arrestor 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PVT 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Panel Removal 130. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 131. . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble Shooting 135. . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram 140. . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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. If your vehicle is stolen, these numbers are essential
to its recovery and identification.
NOTE: Record your vehicle’s ID numbers in the spaces provided.
Remove the spare key and store it in a safe place. Your key can be
duplicated only by mating a Polaris key blank with an existing key.
NOTE: If both keys are lost, see your dealer for ignition switch
replacement.
2
1
Frame VIN:
Engine Serial Number:
Vehicle Model Number:
Dealer Imprint:

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VEHICLE SPECIFICATIONS
SPORTSMAN 700
Gross Vehicle Weight 1240 lbs.
Fuel Capacity 4.75 U.S. Gallons
Towing Capacity 1500 lbs
Hitch Tongue Capacity 150 lbs
Overall Length 85”
Overall Width 46”
Overall Height 47”
Wheelbase 50.75
Ground Clearance 11”
Dry Weight 740 lbs
Minimum Turning Radius 71.5”
Engine Oil Capacity 2 Quarts
Coolant Capacity 3.2 Quarts
Engine EH68ALOE1
Displacement 683
Bore x Stroke 80 x 68
Pilot Jet 45
Main Jet 155
Needle Jet P-6(829)
Jet Needle 4HB41-4
Pilot Screw 1.5
Alternator Output 300 Watts @ 3000 rpm
Compression Ratio 9.78:1
Starting System Electric
Carburetor BST 34mm
Ignition System CDI
Ignition Timing 34 BTDC @ 3500 RPM
Spark Plug / Gap RC7YC / 0.9 mm / .035 in
Lubrication System Pressurized Wet Sump
Driving System Type 4 Wheel Independent Shaft

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VEHICLE 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
Front Brake Hydraulic Disc
Rear Brake Hydraulic
Parking Brake Hydraulic lock, all wheel
Headlight (watts) 1 - Single Beam on Handlebar (50)
2 - Single Beam on Grill (27)
Taillights (watts) 8.26
Brake Light (watts) 26.9
Instrument Cluster LCD
Clutching and Jetting Charts
Altitude AMBIENT
TEMPERATURE
Below 40°F
Below 5°C
+40°Fand above
+5°C to & above
Meters
(Feet)
0-1800
(0-6000)
175 162.5
1800-3700
(6000-12000) 150 140
Altitude Shift
Weight Drive Clutch Spring Driven Clutch
Spring
Helix*
Meters
(Feet) 0-1800 (0-6000) 20-56 PN 5631315 Blue/Green PN 7041157 White/Yellow PN 7041635 EBS PN 5132751
1800-3700
(6000-12000) 20-54 PN 5631214 Blue/Green PN 7041157 White/Yellow PN 7041635 EBS PN 5132751
EBS models require no helix / spring adjustment