Polaris 2004 SPORTSMAN Bedienungsanleitung

Owner's Manual

for Vehicle Maintenance

and Safety

Owner's Manual

for Vehicle Maintenance

and Safety

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

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.

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

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.

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.

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.

31XX

400/500

600/700

Frame VIN:

Engine Serial Number:

Vehicle Model Number:

Key Number:

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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.

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

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