2005 Polaris Sportsman 600 Owners Manual

2005 Polaris Sportsman 600 Manual

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2005 Polaris Sportsman 600 manual content summary:

  • 2005 Polaris Sportsman 600 | Owners Manual - Page 1
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 2
    NEVER USE WITH DRUGS OR ALCOHOL NEVER: Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate and protective apparel. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. Part No. 9919412 Rev 04 PRINTED IN THE USA
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 3
    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.
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 4
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 5
    of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2005 Sportsman 400/500/600/700 Owner's Manual P/N 9919412 2
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 6
    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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 7
    4
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 8
    CONTENTS 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 ...114 SPECIFICATIONS ...118 WARRANTY ...126 INDEX ...131 5
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 9
    6
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 10
    VEHICLE IDENTIFICATION NUMBERS Record your ATV's identification numbers and key number 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 one of your existing keys, so if both keys are lost, the ignition
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 11
    of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 12
    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 7172748 SAFETY WARNING 7172566 ATTENTION S Operation of this vehicle without the air filter element will severely damage the
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 13
    SAFETY Safety Decals and Locations WARNING S S 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 14
    sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner's Manual. 7172564 SAFETY MANUFACTURED BY: POLARIS IND. INC. DATE: VIN: ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 15
    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 16
    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. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 17
    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. WARNING The damage to the vehicle. NOTE: A note will alert you to important information or instructions. 14
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 18
    Safety 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 Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 19
    . To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 20
    exceed the stated load capacity for your ATV. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 21
    Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident the skills learned in the course and the operating techniques described in the owner's manual. For more information about the training course, contact an authorized ATV dealer or
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 22
    Operator Safety 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 23
    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. In many states
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 24
    Operator Safety 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 25
    ATV before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual. 22
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 26
    Operator Safety 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 27
    loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. 24
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 28
    could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner's manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 29
    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. See page 59. Always check the terrain carefully before descending a hill. Shift
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 30
    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 manual. See page 60. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 31
    uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. See page 60. 28
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 32
    such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 33
    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-
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 34
    and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. See page 52. WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 35
    injury or death. Always remove the ignition key when the vehicle is not in use. 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 36
    Engine Electrical Switches CONTROLS 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. 4 2 1 3 Mode/Reverse Override Switch (1) - This vehicle is
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 37
    to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 38
    Light Switches NOTE: CONTROLS 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. The lights won't work unless the key is in the ON position and the shut-off switch is in the RUN position. WARNING Operating the ATV on
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 39
    CONTROLS Master Cylinder The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full.
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 40
    Parking Brake CONTROLS 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. Setting the Parking Brake 1 1. Place the transmission in PARK. 2. Squeeze and
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 41
    CONTROLS Auxiliary Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 42
    Choke CONTROLS The choke assists in starting a cold engine. Refer to the engine starting procedure on page 50 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has two positions: OFF: For vehicle storage and when
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 43
    CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift into HIGH or PARK, you must first apply the auxiliary brake to
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 44
    All Wheel Drive (AWD) System FEATURES 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 1 times. When the switch is on, the
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 45
    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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 46
    = Park 2. AWD Indicator - This indicator illuminates when the electrical portion of the AWD system is enabled. 9 1 3. Engine Hour Display Indicator 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is being operated at an RPM
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 47
    FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode button to
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 48
    Instrument Cluster Rider Information Center FEATURES Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. To leave the diagnostic mode,
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 49
    faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to 0. You can then reset
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 50
    Fuel Safety OPERATION 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 51
    OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as 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. Careful treatment
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 52
    Pre-Ride Inspection OPERATION WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Pre-Ride Checklist Item Brake system / lever travel Brake fluid Auxiliary brake
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 53
    OPERATION Starting the Engine Starting a Cold 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. Place the transmission in PARK and lock the parking brake. 2. Turn
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 54
    Starting the Engine Starting a Warm Engine OPERATION Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in PARK. 2. Lock the parking brake, turn the fuel tank
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 55
    and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decals. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 56
    extra caution. Always attach the tow load to the hitch point designated for your vehicle. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. S USE EXTREME CAUTION when
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 57
    OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 58
    tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 59
    OPERATION Driving Safely 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 60
    injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. 57
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 61
    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 the most dangerous type of driving encountered and should be avoided if at all possible. If you do enter into a situation
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 62
    down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 63
    on hills, and follow proper operating procedures outlined in the owner's manual. If the vehicle stalls while climbing a hill, never back it of the vehicle, turn the handlebars full left. 5. While holding the service brake, release the parking brake lock and slowly allow the vehicle to roll
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 64
    the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine. NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 65
    OPERATION Driving Safely 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.
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 66
    Driving Safely Driving in Reverse OPERATION Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 67
    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in PARK. 3. Set the parking brake. 4. Always block the rear wheels on the downhill side as shown in the
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 68
    and operation of this vehicle. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 69
    upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 70
    Periodic Maintenance Chart Item MAINTENANCE AND LUBRICATION Maintenance Interval Remarks Perform all services at whichever maintenance interval is reached first. (whichever comes first) Hours Calendar Miles (Km) 10 H 20 H 25 H 25 H 25 H 25 H Pre-Ride Pre-Ride Pre-
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 71
    ) 1000 (1600) 1000 (1600) " Cooling hoses " Engine mounts Exhaust muffler/ pipe " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 72
    wheel J Brake fluid Spark arrestor E Idle speed J Toe adjustment Headlight aim " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 73
    MAINTENANCE AND LUBRICATION Periodic Maintenance Record Maintenance Interval Performed Servicing Servicing Date Dealer or Person Use the following chart to record periodic maintenance. Remarks 70
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 74
    lower control arms have grease fittings, but these components are greased "for life" at the factory. No additional lubrication is needed. Lubrication Guide Key " L Polaris Premium All Season Grease or grease conforming to NLGI F More often under severe use No. 2, such as Conoco Superlube M or
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 75
    MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 76
    Oil Check MAINTENANCE AND LUBRICATION The 400/500 oil dipstick and fill tube (1) are located on the left side of the ATV. The 600/700 dipstick/oil fill (2) is located on the engine and is accessible on the left side of the ATV. NOTE: A rising oil level between checks in cool weather driving can
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 77
    MAINTENANCE AND LUBRICATION Oil and Filter Change Oil Change (400/500) 1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine. 2. Run the engine for two to three minutes, then turn it off. 3. Place a drain pan
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 78
    Oil Change (400/500) MAINTENANCE AND LUBRICATION 7. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 8. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition.
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 79
    MAINTENANCE AND LUBRICATION Oil Change (400/500) Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line (1) approximately 2I from the oil tank (2), between the end of
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 80
    Oil Change (600/700) MAINTENANCE AND LUBRICATION 1. Place the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area around the drain plug. 4. Place a drain pan beneath engine crankcase and remove the drain plug. CAUTION Hot oil can
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 81
    MAINTENANCE AND LUBRICATION Transmission Oil (400/500) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 113 for the part numbers of Polaris
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 82
    Front Gearcase Oil MAINTENANCE AND LUBRICATION Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Maintain the oil level even with the bottom of the fill hole threads (1). We recommend the use of Polaris Premium Demand
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 83
    MAINTENANCE AND LUBRICATION Transmission Oil (600/700) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Maintain the transmission oil level at the bottom of the fill plug hole (1). We recommend the use of Polaris Premium
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 84
    Rear Gearcase Oil (600/700) The rear gearcase fill plug (1) is located on the rear of the gearcase. Always check and change the rear gearcase oil at the intervals outlined in the 2 Periodic Maintenance Chart beginning on page 66. Maintain the rear gearcase oil level (2) even with the bottom of the
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 85
    MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 86
    Engine Cooling System Coolant Level MAINTENANCE AND LUBRICATION 1 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 87. Maintain the coolant level between the minimum and maximum marks on the bottle (
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 87
    MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. The following checks are recommended to keep the brake system in good operating condition. Check more often if
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 88
    Brakes MAINTENANCE AND LUBRICATION 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″
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 89
    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. Do not attempt to adjust
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 90
    Side Panel Removal MAINTENANCE AND LUBRICATION 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. Reinstall the
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 91
    as described on the decal on your ATV and in the owner's manual. Always use original equipment size and type when replacing tires. Make sure bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Wheel Removal
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 92
    affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 2. Place the wheel on the wheel hub with the valve stem toward the
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 93
    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1 1. Remove the seat, release the air box cover clips, and 2 remove the air box cover. 2. Loosen the clamp your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service. 90
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 94
    normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Allow lamps to cool before servicing. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Remove the screw from the rear
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 95
    MAINTENANCE AND LUBRICATION 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. 2. Measure the distance
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 96
    Lights MAINTENANCE AND LUBRICATION Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 97
    MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 98
    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 white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 99
    . 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. NOTE: If water has been ingested into the PVT, follow the procedure on
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 100
    Spark Arrestor MAINTENANCE AND LUBRICATION 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 101
    MAINTENANCE AND LUBRICATION 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 102
    procedures. See your dealer as outlined in the owner's manual. This PVT system is intended for use on Polaris products when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug and service as soon as possible. 99
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 103
    MAINTENANCE AND LUBRICATION Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Always
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 104
    Battery MAINTENANCE AND LUBRICATION Battery Removal 1. Disconnect the hold-down strap holding the battery in position, and remove battery cover. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive)
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 105
    the negative (black) cable last. Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installation of a YUASA activated, sealed battery. Read all instructions before proceeding with the installation of this battery. The YUASA activated, sealed battery is
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 106
    the voltage is less than 12.8 volts, recharge the battery. NOTE: When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging. WARNING An overheated battery could explode, causing
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 107
    MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your ATV. See your Polaris dealer.
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 108
    may force water past seals. Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 109
    following the instructions on the can. Run the engine for several minutes so the Carbon Clean reaches the carburetor. Turn the engine off. 2. Support the front lubrication guidelines in the Maintenance Section of the service or owner's manual to completely grease and lubricate the entire vehicle with
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 110
    Test engine coolant strength and change if necessary. Coolant should be replaced every two years. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires 1-2" off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 111
    apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. 4. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 112
    in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Locate handlebar bolts (1) by removing the upper 1 headlight pod. 2. Loosen the four bolts. 3. Adjust the handlebar to the desired height. Be sure
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 113
    ADJUSTMENTS Carburetor/Idle RPM 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 114
    Throttle Cable Freeplay ADJUSTMENTS Throttle cable freeplay is adjusted at the handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever. NOTE: While adjusting
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 115
    NOTES 112
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 116
    POLARIS PRODUCTS Part No. 2870791 2871281 2871844 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2872073 2872348 2871323 2871534 2872889 2871326 2870652 2870990 2872893 2871956 Description Engine Lubricant Fogging Oil (12 oz. Aerosol)
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 117
    TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in high range. Starting out going up a steep incline. performance. Check for fouled plugs or foreign material in gas tank, fuel lines, or carburetor. Contact your dealer for service. 114
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 118
    TROUBLESHOOTING 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
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 119
    TROUBLESHOOTING Engine Backfires Possible Cause Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 120
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 121
    SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight Towing Capacity Hitch Tongue Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 122
    SPECIFICATIONS SPORTSMAN 400 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - Forward Drive Ratio - Front Tire, Front Tire, Rear Front Brake Rear Brake Auxiliary Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brakelight Instrument
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 123
    SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 124
    SPECIFICATIONS SPORTSMAN 500 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - Forward Drive Ratio - Front Tire, Front Tire, Rear Front Brake Rear Brake Auxiliary Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brakelight Instrument
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 125
    SPECIFICATIONS SPORTSMAN 600 Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 126
    SPECIFICATIONS SPORTSMAN 600 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size - Front Tire Size - Rear Front Brake Rear Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight (watts) Taillights
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 127
    SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer Towing Capacity* Front Rack Capacity Rear Rack Capacity Hitch Tongue Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 128
    SPECIFICATIONS SPORTSMAN 700 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size - Front Tire Size - Rear Front Brake Rear Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brake
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 129
    COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. 126
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 130
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 131
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 132
    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. Outside the Country where your vehicle
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 133
    where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 134
    INDEX A Accessories ...66, 104 ADJUSTMENTS ...109-111 Age Restrictions ...13 Air Filter Service ...90 All Wheel Drive ...41 Automatic Transmission ...40 Auxiliary Brake ...85 AWD ...41 D Driving on Slippery Surfaces ...56 Driving Over Obstacles ...62 Driving Procedures ...54
  • 2005 Polaris Sportsman 600 | Owners Manual - Page 135
    ...91-94 Low Beam Adjustment ...92 Low Range ...98 Lubrication Guide ...71 M Main Switch ...33 MAINTENANCE AND LUBRICATION ...66-108 Maintenance (Sportsman 600/700) ...80 Transporting the ATV ...108 Trip Meter ...44 TROUBLESHOOTING ...114-117 Turning Around on a Hill ...60 P Parking Brake ...37
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