Polaris Sprotsman MV7, Owner'S Manual

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Page 3: ...ed 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 The engine exhaust from this product contains chemicals kno...

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Page 5: ...minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liab...

Page 6: ...d 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...

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Page 8: ...ICATION NUMBERS 7 SAFETY 8 CONTROLS 33 FEATURES 41 OPERATION 49 EMISSION CONTROL SYSTEMS 68 MAINTENANCE AND LUBRICATION 69 ADJUSTMENTS 109 SPECIFICATIONS 112 POLARIS PRODUCTS 114 TROUBLESHOOTING 115 W...

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Page 10: ...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 swi...

Page 11: ...ructions of the decals on the vehicle If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge T...

Page 12: ...duce 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 7173016 ATTENTION S Operation of this vehicle...

Page 13: ...rts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed S Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive...

Page 14: ...DE HITCH MAX VERTICAL WEIGHT 150 LBS 68KG Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may resul...

Page 15: ...stitute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protecti...

Page 16: ...t 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...

Page 17: ...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 saf...

Page 18: ...including a dirt or gravel road S Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jack...

Page 19: ...er attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use pr...

Page 20: ...ETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public...

Page 21: ...e and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 WARNING POTENTIAL HAZAR...

Page 22: ...allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking...

Page 23: ...POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe...

Page 24: ...fore or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZA...

Page 25: ...r stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility o...

Page 26: ...into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POT...

Page 27: ...e on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain...

Page 28: ...per hill climbing 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 careful...

Page 29: ...res for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 61 Always check the terrain carefully before descend...

Page 30: ...t 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 62 Use extra caution when turning on any hill Avoid crossin...

Page 31: ...l Apply the brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply th...

Page 32: ...nual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD...

Page 33: ...nts and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after le...

Page 34: ...re information WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of...

Page 35: ...ng systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased ri...

Page 36: ...s purpose is to provide the operator with a quick means of engine shutdown in case of an emergency Main Switch 3 To start the engine slide the stop switch to the center RUN position and turn the main...

Page 37: ...y during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever 1 The throttle lever is spring loaded Engine speed returns to idle when the lever is r...

Page 38: ...in conditions of reduced visibility such as fog rain and darkness Brake Lever The front and rear brakes are applied by squeezing the brake lever 1 toward the handlebar The front and rear brakes are h...

Page 39: ...hen checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only See page 114 for the part numbers of Polaris products WAR...

Page 40: ...rake lock 2 forward to engage the brake Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards S T...

Page 41: ...aris ATV has an auxiliary brake 1 for added safety It s located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system...

Page 42: ...first Switch to the front tank when the rear tank is empty It will be easier to monitor remaining fuel at the front tank gauge FRONT TANK Use the front tank fuel supply when the rear tank is empty NOT...

Page 43: ...or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Whenever the ATV is left unattended always...

Page 44: ...ON position NOTE If the engine is cold use the choke as outlined on page 52 4 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke w...

Page 45: ...le speed and cargo weight when air pressure is lost in run flat tires could result in loss of control or tire damage This could lead to serious injury or death If you must operate the vehicle with fla...

Page 46: ...s on See page 33 There is no limit to the length of time the vehicle may remain in AWD Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle...

Page 47: ...to approximately 7 9 mph Refer to page 33 for additional information 1 Rider Information Center 2 Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition e...

Page 48: ...c Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery warning may also occur under n...

Page 49: ...ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button...

Page 50: ...t the park brake and shift the transmission to neutral 3 Hold the mode reverse override button and turn the key switch on 4 Release the switch as soon as the display is activated The initial screen di...

Page 51: ...ash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increm...

Page 52: ...Do not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run...

Page 53: ...CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another 0W 40 API certified SH oil Never substitute or m...

Page 54: ...Inspect condition and pressure 87 Wheels fasteners Inspect ensure fastener tightness 88 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 75 Coolant level if applic...

Page 55: ...engine oil will increase wear on engine components 4 Turn the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 5 Turn the ignition key past the ON position to engage...

Page 56: ...ver choked when warm depress the throttle lever fully while cranking to aid in starting 5 Release the throttle lever immediately after the engine starts If the engine does not start and all conditions...

Page 57: ...e 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 low as possible When ope...

Page 58: ...table operating conditions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely f...

Page 59: ...to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin...

Page 60: ...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...

Page 61: ...ning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow t...

Page 62: ...rottle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle WARNING Braking and handling are greatly affected when operating in hilly terra...

Page 63: ...can be the most dangerous type of driving encountered and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Le...

Page 64: ...our weight to the rear of the vehicle 3 Slow 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 oc...

Page 65: ...loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25_ maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in...

Page 66: ...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 around to your right until it s pointing across the h...

Page 67: ...and rear gearcases and all grease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance...

Page 68: ...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 obs...

Page 69: ...s or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines...

Page 70: ...ng 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...

Page 71: ...aris specifications to achieve optimal performance Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authori...

Page 72: ...rage 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...

Page 73: ...when visible Coolant Daily Check level daily change coolant every 2 years Headlamp tail lamp Daily Check operation E Air filter main element Weekly Inspect replace as needed Recoil housing Weekly Drai...

Page 74: ...ength seasonally pressure test system yearly E Engine oil change 100 H 6 M 1000 1600 Perform a break in oil change at one month E Oil filter change 100 H 6 M 1000 1600 Replace with oil change E Oil ta...

Page 75: ...000 1600 Inspect clean replace worn parts J Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed J Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000...

Page 76: ...Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging Item Lube Method Engine Oil Polaris Premium 4 Synthetic 0W40 Add to proper level on dip sti...

Page 77: ...breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris...

Page 78: ...1 Position the vehicle on a level surface 2 Remove the dipstick and wipe it dry with a clean cloth NOTE Lift the lever lock 2 to remove the dipstick 3 Reinstall the dipstick completely but do not lock...

Page 79: ...install the drain plug and torque to 20 ft lbs 27 Nm 8 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove 9 Using a clean dry cloth clean th...

Page 80: ...rt numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug 2 and view the oil level 3 Add the recommended gearcase oil as needed to bring the level to th...

Page 81: ...2 is located on the right side of the ATV behind the footwell The transmission drain plug 3 is located on the bottom left hand side of the gearcase Oil Check 1 Remove the footwell see page 86 2 Remove...

Page 82: ...r recommended lubricants capacities and torque specifications See page 114 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the side fill plug and...

Page 83: ...fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and dist...

Page 84: ...ration 2 Remove the rack 3 Remove the pressure cap 1 4 Using a funnel slowly add coolant through the radiator filler neck 5 Reinstall the pressure cap 6 Reinstall the front rack NOTE Use of a non stan...

Page 85: ...y system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess co...

Page 86: ...to 1 4 3 6 mm toe out 1 Set the handlebars in a straight ahead position NOTE The steering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight...

Page 87: ...an lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always keep brake fluid at an adequate level see...

Page 88: ...E Pads should be changed when worn to 3 64 1 cm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can b...

Page 89: ...ll the panel downward and rearward to remove it from the ATV 4 Reinstall the side panel by reversing the removal procedure Footwell Removal 1 Remove the four screws 1 on the bottom of the footwell 2 U...

Page 90: ...talled properly Always replace tires when the tread depth measures 1 8 3 mm or less Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less See illustration Front Wheel Hub...

Page 91: ...t have a cotter pin installed See your Polaris dealer 2 Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation 3 I...

Page 92: ...se 1 To access the breather filter 3 remove the left side panel as outlined on page 86 The breather filter is on the hose that runs between the engine and air box 2 Remove the clamps and pull the filt...

Page 93: ...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 of the pod 3 Lift the...

Page 94: ...rt the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 1 cm below the mark on the wall NOTE...

Page 95: ...e wiring harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to re...

Page 96: ...the new headlamp 4 Install the new headlamp and harness assembly into the headlight assembly Turn the headlight harness counterclockwise to secure Taillight Brakelight Lamp Replacement 1 Remove the ta...

Page 97: ...is gray tan or light brown There 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 shoul...

Page 98: ...it if water is present Filter replacement is required if water intrusion is evident 3 Turn the fuel valve off 4 Remove the spark plug 5 Loosen the carburetor drain screw 1 6 Turn the engine over seve...

Page 99: ...will enter the recoil housing if the starter handle is disengaged from the rope guide when under water The drain screw is located at the bottom of the recoil housing Use a wrench to remove the screw...

Page 100: ...nder the vehicle while it s inclined 1 Remove the arrestor clean out plug 1 from the bottom of the muffler 2 Place the transmission in PARK and start the engine 3 Purge carbon from the system by momen...

Page 101: ...above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be r...

Page 102: ...nded maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the P...

Page 103: ...p water into a conventional battery WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with wat...

Page 104: ...tery in the battery holder 2 Install the battery vent tube NOTE The vent tube must be free of obstructions and securely installed If not battery gases could accumulate and cause an explosion The tube...

Page 105: ...alled Replenishing Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks 1 To re...

Page 106: ...ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a cha...

Page 107: ...rs may force water past seals Stabilize the Fuel 1 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to both tanks Follow the instructions on the container for the recommended amount...

Page 108: ...espoons of Premium 4 Synthetic 0W40 engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE Do this carefu...

Page 109: ...attery in a cool dry place Charge can be maintained easily by using Polaris Battery Tendert charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tendert ca...

Page 110: ...ly and liberally 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 t...

Page 111: ...nd remove the key to prevent loss during transporting 2 Place the transmission in PARK and lock the parking brake 3 Turn the fuel valve off and be sure the fuel caps oil cap and seat are installed sec...

Page 112: ...ing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment pr...

Page 113: ...e required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adju...

Page 114: ...juster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 1 5 3 mm freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever ba...

Page 115: ...27 cm Wheelbase 50 75 in 129 cm Ground Clearance 10 5 in 26 7 cm Minimum Turning Radius 71 5 in 181 6 cm unloaded Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 3 2 qts 3 l Gearcase Oil Capacity Fro...

Page 116: ...of travel Shock Adjustment Rear Spring Preload Adjust Headlight 1 Single Beam on Headlight Pod 50 w 2 Single Beam on Grill 27 w Taillights 8 26 w Brake Light 26 9 w Instrument Cluster LCD Jetting Char...

Page 117: ...Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460...

Page 118: ...for efficient enga gement Towing pushing at low RPM low ground speed Use low range only Utility use plowing snow dirt etc Use low range only Stuck in mud or snow Shift the transmission to low range an...

Page 119: ...el Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessa...

Page 120: ...e ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel vent line Inspect and repla...

Page 121: ...battery voltage Recharge battery to 12 5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Elec...

Page 122: ...gistration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLET...

Page 123: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels tha...

Page 124: ...egistration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servi...

Page 125: ...ling 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 Co...

Page 126: ...d outside of the country where it was pur chased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Ve...

Page 127: ...124 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 128: ...125 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 129: ...126 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 130: ...on Slippery Surfaces 58 Driving Over Obstacles 65 Driving Procedures 56 Driving Safely 54 67 Driving Through Water 64 Driving Uphill 59 E Electrical Switches 33 Electromagnetic Interference 68 EMISSI...

Page 131: ...ding Gear 12 SAFETY 8 32 Safety Decals and Locations 8 11 Safety Training 13 Severe Use 69 S Side Panel Removal 86 Sidehilling 60 Spark Arrestor 68 97 Spark Plug Removal and Replacement 94 Spark Plugs...