Polaris 500 HO International manual

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P antone 425 C W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without proper training or instruction. S at speeds too fast for your skills or the conditions. S on public roads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steering and increase risk of losing[...]

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles Always follow the instructions and recommendations in this m[...]

2 POLARIS and POLARIS TH E W A Y OUT are regi stered tradem arks of Polaris Indus- tries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discrep[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Emission Control Systems . . . . . . . . . . . . [...]

4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal inju ry hazard. W ARNING A W ARN ING indicates a hazardous[...]

5 INTRODUCTION Failure to follow the warnings in this manu al can result in serious injury or dea th. This Polaris vehicl e is not a toy and can be hazardo us to operate. A collision or rollover can occur quickly , even during routine maneuvers, if you fail to take proper precautions. Read and understand your owner's manual and all warnings be[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your k ey number) and mating it with one of your existi ng keys. The ignition switc[...]

7 SAFETY Operator Safety Serious injury or death can result if you do not follow the instructions and procedures listed here a nd throug hout this manual. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instruction. T [...]

8 SAFETY Operator Safety Always wear an approved helmet that fits properly . Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume al cohol or drugs before or while operating this vehicle. Never operate at excessive speeds. T ravel and turn at speeds appropriate for the terrain, visibility , operati[...]

9 SAFETY Operator Safety Always inspect your Polaris vehicle before each use to verify that it' s in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 53. Keep both hands on the handl ebars. Keep your feet on the footrests. Always travel slowly when operating on unfamiliar terrain. Use[...]

10 SAFETY Operator Safety If the vehicle has been i nvolved in an accident, always have an authorized Polaris dealer in spect the entire vehicle for possible damag e, including (but not limited to) b rake, throttle and steering systems. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempti[...]

11 SAFETY Operator Safety Always follow the procedures outl ined in this manual for b raking if you stall or roll backwards whil e climbing a hill. Never back down a hill. See page 26. Always follow the procedures outl ined in this manual for operating over obstacles. See pa ge 21. Always follow the procedures outl ined in this manual for operating[...]

12 SAFETY Operator Safety Always follow the procedures outl ined in this manual for driving in reverse. See page 31. Always use the size and type of tires specified for your vehicle. Main tain the proper tire pressure. Never modify this Polaris vehicle through improper installation or use of accessories. Never exceed the stated load capacity for yo[...]

13 SAFETY Operator Safety Never operate the ve hicle on a frozen body of water . Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control. Avoid sudden turns or swif t movement of the handlebars. Always remove the ignition key when the vehicle is n ot in use to prevent unauthorized use or ac[...]

14 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your p rotection. Read and follow the instructions on each label carefully . If a label becomes illegible or comes of f, contact your Polaris dealer to purchase a replacement. Replacement safety labe ls are provided by Polaris at no charge. The part number is [...]

15 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING - NEVER ride as a passenger . Pa ssengers can caus e a loss of control, resulting in SEVERE INJUR Y or DEA TH. Tire Pre ssure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAP ACITY (Gro ss V ehicle Weight) INCLUDING MACHINE, DRIVER AND C[...]

16 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury . Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Ca nada bear a U.S. Dep artment of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE m[...]

17 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE ) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make[...]

18 SAFETY Driving Safely Driving Procedures 1. Sit upright. Kee p your feet on th e footrests. Keep both hands on the handlebars. 2. Apply the brake s. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check your surroun dings and determine your path of travel. 6. Release the brakes. 7. Slowly squeeze the thrott[...]

19 SAFETY Driving Safely T urning the V eh icle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Acti- vate the right signal before a right turn. 2. Steer i n the direction of the turn, leaning your upper b ody to the inside of the turn while supporting you r weight on the ou[...]

20 SAFETY Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as we t trails, gravel, snow or ice, follow these precautions: 1. Slow down before driv ing onto slippery surfaces. 2. Engage A WD before wheels begin to lose traction. 3. Be alert. 4. W atch the trail. 5. A void quick, sharp turns. Tip : T o c[...]

21 SAFETY Driving Safely Driving Over Obst acles 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. W atch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. A void hazards such as logs, rocks and low branches. [...]

22 SAFETY Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. Check the terrain carefully . 3. A void hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill. 6. Keep your feet on the fo otrests. 7. Drive at a steady rate of spe[...]

23 SAFETY Driving Safely Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins r olling downhill, never apply engine power . Never apply the brakes aggr essively while r olling backwar ds. Apply the brakes gradually . When fu lly stopped, lock the hydraulic parking brak e. See page 3 9. Dismount on the uphill s[...]

24 SAFETY Driving Safely Driving on a Sidehi ll (Sidehilling) A void crossing the side of a hill (sid ehilling) if possible. If sidehilling is necessary , follow these precautions: 1. Slow down. 2. A void hills with excessively slippery or loose surfaces. 3. Shift your weight uphill. 4. A void crossing the sides of steep hills. 5. Keep your feet on[...]

25 SAFETY Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Check the terrain carefully . 2. A void hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. A void driving downhill at an angle, which can ca use the vehicle to pitch sharply to one side. Drive straigh[...]

26 SAFETY Driving Safely T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop the vehicle. Keep your weight uphill. 2. Lock th e hydrau lic parking brake. 3. Leave the transmission in forw ard gear . Tu rn the engine of f. 4. Dismount on the uphill side [...]

27 SAFETY Driving Safely T urning Around on a Hill (K-T urn) 8. Lock the hydraulic parking brake. 9. Remount from the uphill side. Keep your weight uphill. 10. Apply the foot brake. 1 1. W ith the transmission still in forward, start the engine. 12. Squeeze and release the brake le ver to release the pa rking brake. 13. Release the foot brake and d[...]

28 SAFETY Driving Safely Driving Through W ater Follow these procedures wh en driving through water: 1. Check water depth and cu rrent before crossing. 2. A void operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slow ly , balance your weight carefully and avoid sudden movements. Mainta in a slo w and stead[...]

29 SAFETY Driving Safely Driving Through W ater If your vehicle becomes fully immersed , and it's impossible to take it to a dealer before starting it, follow the steps described on page 94. Have the vehicle serviced by your dealer promptly . If water has been ingested into the transmission (PVT), follow the pro- cedure on page 99 . Always fol[...]

30 SAFETY Driving Safely Parking on an Incline A void parking on an incline. If it' s unavoidable, follow these precau- tions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Always block the rear wheels on th e downhill side. 4. T urn the fuel valve off.[...]

31 SAFETY Driving Safely Driving in Reverse Follow these precautions w hen operating in reverse: 1. A void backi ng downhill. 2. Always check for obsta- cles or people behind the vehicle before backing. 3. Drive slowly . 4. Apply the foot brake lightly for stopping. 5. A void turning at sharp angles. 6. Do not use the override switch unless additio[...]

32 SAFETY Driving Safely Hauling Cargo Overloading the vehicl e or carrying or to wing cargo i mproperly can al ter vehicle handling and may cause loss of control or brake instability . Always follow these precautions when hauling cargo . • Read and understand the load distribut io n warnings listed on the vehicle warning labels. • Never exceed[...]

33 SAFETY Driving Safely Hauling Cargo T owing Loads T owing is a pproved OFF-ROAD ONL Y . Operating this vehicle with a trailer on public roads is prohibited. Do not exceed the maximum capac- ities when towing. Do not tow any trailer on a grade steeper than 15 ° . Using an improper hitch or exceeding the maximum tongue weight capacity can result [...]

34 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 45. T o gain additional power while o pera ting in reverse, press the override switch before opening th e throttle. This will canc el the reverse speed limit function. The override switch als[...]

35 FEA TURES AND CONTROLS Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position. Do not attach a large key fob or key ring to the main switch. It m[...]

36 FEA TURES AND CONTROLS Switches All Wheel Drive Switch See page 44 for all wheel drive information. Hazard W arning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously . Use this feature to alert others of an emergency or other situation requiring caution. T urn Signal Switch Push the toggle switch eithe[...]

37 FEA TURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. Failure to check or maintain proper opera tion of the throttle system can result in an accident if the throttle lever sticks during operation. Check th e lever for proper ope[...]

38 FEA TURES AND CONTROLS Foot Brake The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with yo ur foot to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure. Hand Brake Lever The hand brake ope[...]

39 FEA TURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PA R K . 2. Squeeze the brake lever toward the handlebar . 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lock, squeeze and release the brake lever . Operating the vehicle while the[...]

40 FEA TURES AND CONTROLS S teering Lock Lock the steering to prevent unau- thorized use or theft of the vehicle. Tip : Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 1. T urn the handlebars to the full left position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key . 4. Reverse[...]

41 FEA TURES AND CONTROLS Fuel T ank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gaso- line with a minimum pump octane of 87 . Do not use fuel with ethanol content gr eater than 10%, su ch as E-85 fuel. Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hou rs of operat[...]

42 FEA TURES AND CONTROLS T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicl e. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the vehicle is left unattended, always place the transmission in P ARK. The transmission is locked when it’ s in PA R K . Shifting gears with the engine [...]

43 FEA TURES AND CONTROLS Recoil St arter (if equipped) If the battery is too weak to start the engine, use the recoil starter . Follow the starting procedures on page 54, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly . 2. Pull slightly until the starter mechanism engages[...]

44 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The A WD switch may be turne d on or off while the vehicle is moving. A WD will not engage until engine speed is below 3100 RPM. A WD remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in A WD. If the switch is turned of f while the [...]

45 FEA TURES AND CONTROLS Instrument Cluster Y our vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also include[...]

46 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over - voltage may have occurred and the instrument cluster ma y have shut of f to protect the el[...]

47 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center St andard Modes Use the MODE button to toggle thro ug h the mode options. Th e reverse override button is also the MODE button. See page 34. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odomete r records the m iles traveled by the vehicle[...]

48 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when th e gauge is in the diagnostic mode. T o exit the diagnostic mode, turn th e key switch of f and on. Any mov e- ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn th [...]

49 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Screen V iew this screen to check battery voltage level. T achometer Screen V iew the tachometer to check engine speed. A WD Diagnostic Screen The gauge indicates whether or not cu rrent is flowing through the A WD coil (only on models with switch[...]

50 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval T o enable or disable the service interval: 1. Enter the diagnostic mode. 2. T oggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center[...]

51 OPERA TION Fuel Safety Gasoline is highl y flammable and explosive under certain conditions. • Use extreme caution whenever handli ng gasoline. • Refuel with the en gine stopped. Refuel outdoors or in a well-ventilated area. • Never fill a fuel container while it's on the vehicle. S tatic electricity betwe en the rack and container co[...]

52 OPERA TION Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full ta nk s of gasoline. No single action on your part will in crease the life an d performance of your vehicle more than fo llowing the procedure s for a proper break-in. Careful treatment o[...]

53 OPERA TION Pre-Ride Checklist Item Remarks Page Foot brake Ensure proper operation 38 Hand brake/lever travel Ensure proper operation 79 Brake fluid Ensure proper level 76 Front suspension Inspect, lubricate if necessary 62 Rear suspension Inspect, lubricate if necessary 62 S teeri ng/steering lock Unlock the steering; e nsure free oper- ation 4[...]

54 OPERA TION S t arting the Engine 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. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. T urn the fuel valve on. 4. Sit on the vehicle. Tip : The starter i[...]

55 OPERA TION S t arting the Engine 7. Do not press the thro ttle while starting the engine. T urn the ignition key past the POSITION LIGHTS ON position to engage the starter . Activate the starter for a maximum of five seconds, re leasing the key when the engin e starts. 8. If the engine does not start, release the starter and wait five seconds. 9[...]

56 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with gover nmental noise level requi rements. S p ark A rrestor Y our Polaris vehicle has a spa rk arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor [...]

57 MAINTENANCE Periodic Maintenance Chart Maintenance intervals in th e following chart are based upon averag e riding conditions. V ehicles subjected to severe use mu st be inspected and serviced more frequently . The programmable service interval mo de on the instrument cluster will help determine when maintenance service is due. See page 45. Rec[...]

58 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked with a  could result in component failure and ca use an accident, which may result in seri ous injury or death. Always have an authorized Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subjecte[...]

59 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever main tenance interval is reached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calend[...]

60 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Kilom eters X Engine oil change (break-in) - 1 M - Perform a break-in oil change at one month X General lubrication 50 3 M 800 Lubricate all fittings, pivots, cables, etc. Shift linkage 50 6 M 800 Inspect, lubricate, adjust Q S teering[...]

61 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Kilom eters Q E S park plug 100 12 M 1600 Inspect; replace as needed X [...]

62 MAINTENANCE Lubrication Guide Always check and change fluids and lubricate greaseable compo- nents at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Item s not listed in the chart should be lubri- cated at the General Lubrica tion interval. Item Lube Method Engine Oil P olaris Premium 4 Synthetic 0W-40 See page 63[...]

63 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Polaris recommends the use of Prem ium 4 Synthetic 0W -40 engine oil for this engine. Premium 4 is a fully synthetic, high performance, multi- viscosity oil designed to provide th e ultimate i n lubrication performance and protection. See page 1 16 for[...]

64 MAINTENANCE Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Star t the engine. Allow it to idle for 30 seconds. 4. S top the engine. 5. Remove the dip stick. W ipe it dry with a clean cloth. 6. Reinstall the dipstick completely . 7. Remove the dip stick and check the oil level. Add oil as n[...]

65 MAINTENANCE Engine Oil Oil Change Hot oil may result in serious burns. Do not allow hot oil to contact skin. 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. S tart the engine. Allow it to idle for two minutes. 4. S top the engine. 5. Clean the area around th e drain plug. 6. Place a drain pan under the oil tank[...]

66 MAINTENANCE Engine Oil Oil Change 1 1. Disconnect the lower oil deliv- ery hose and remove the scre en fitting from the oil tank. Clean the fitting. The fitting thr eads must be sealed with LOCTITE PST 505 or PTFE seal tape. 12. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continue[...]

67 MAINTENANCE Engine Oil Oil Change 20. Remove the dipstick. 21. Add 1.9 liters of recommended oil. If the sump is not drained, add about 1.6 liters initially . 22. Reinstall the dipstick. 23. Place the transmission in P ARK. 24. Prime the oil pump using the procedur e on page 68. 25. Stop the engine. Check for oil leaks. 26. Check the oil level. [...]

68 MAINTENANCE Engine Oil Oil Change 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 the vent l ine 5 cm from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit. 2. Star t the engine. A[...]

69 MAINTENANCE T ransmission Oil Maintain the oil level at the botto m of the fill plug hole. Use t he recommended oil. See page 1 16 for the part numbers of Polaris products. Oil Recommendations Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. 4. Check the oil level. Maintain the le[...]

70 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug. 7. Reinstall the drain plug. T orq ue to specification. See page 69. 8. Add the recommended oil. 9. Reinstall the f[...]

71 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Recommendations Use the recommended fluid . Use of other fluids may result in improper operation of components. See page 1 16 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole threads. Fluid Level 1. Position the vehicle on a level surface. 2. [...]

72 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. 4. Remove the drain plug. Drain the fluid into a drain pan. 5. Clean the drain plug. 6. Reinstall the drain plug. T orque to specification. See page 71. 7. Add the recommend ed flu[...]

73 MAINTENANCE Carburetor This vehicle is calibrated at the fa ct ory for optimal performance at alti- tudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degre es C.) or higher . Above 6 000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea ch 1[...]

74 MAINTENANCE Cooling System Any time the cooling system has been drained for maintenance or repair , replace the coolant with a fresh mixture of antifreeze and water . Drain the cooling system every two years. Add fresh coolant. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high qua lity aluminum [...]

75 MAINTENANCE Cooling System Radiator Coolant Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box cover . 2. Open the access door . 3. Remove the radiator pressure cap. 4. If coolant is not visible, slowly add coolant through the rad iator filler neck. 5. Reinstall the pressur[...]

76 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indi cate a fluid leak or low fluid level. A lo w fluid level may also mean that brake pads are wo rn and[...]

77 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handle- bar . Maintain the fluid level 6 mm below the top ed ge of the master cylinder . Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. V iew th e fluid level through the indicator win- dow (eye) on the top of the[...]

78 MAINTENANCE Brake Fluid Foot Brake 1. Position the vehicle on a level surface. 2. Remove the seat. 3. V iew the fluid level in the master cylinder . 4. Maintain the fluid level between the minimum and maximum marks. Do not overfill. Minimum Maximum[...]

79 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by apply- ing the foot brake. The ha ndlebar brake is also hydra ulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good op erat- ing condition. Check more often if brakes are used heavily under [...]

80 MAINTENANCE T oe Alignment Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer . Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Place the handleba rs in a str[...]

81 MAINTENANCE S teering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, se e your Polaris dealer for service before operating the vehicle. Handlebar Adjustment The handlebars can be adjusted for rider preference. Improper adjustment of the hand lebars or incorrect torqui[...]

82 MAINTENANCE Side Panel Re moval 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. W ith a firm motion, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it. Footwell Removal 1. Remove the four screws on the bottom of the footwell. 2. Use a flat screw[...]

83 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and sli de it far enough to ex pose the end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1.6-3.2 mm[...]

84 MAINTENANCE Ti r e s Operating your vehicle with worn tires, i mproperly in flated tires, no n-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. • Maintain proper tire pressure as described on the lab el on your vehicle and in the specifications sectio n of the owner's manu al. • Use [...]

85 MAINTENANCE Ti r e s Wheel Removal/Installation Always use original equipment size and type when re placing tires. Install wheels properly . 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Loosen the wheel nuts slightly . 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the gro[...]

86 MAINTENANCE Air Filter Always clean and replace the air and br eather filters at the intervals out- lined in the Periodic Maintena nce Chart beginn ing on page 57. 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the seat. 4. Release the air box cover clips. 5. Remove the air box cover . 6. Loosen the hos[...]

87 MAINTENANCE Breather Filter/Hose The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 82. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Rep l[...]

88 MAINTENANCE Light s Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in P ARK. 3. Measure the distance from the floo r to the center of the headlight and make a mark on the wall a[...]

89 MAINTENANCE Light s Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and t aillights frequently . Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen la[...]

90 MAINTENANCE Light s T aillight Lamp Replacement 1. Place the transmission in PA R K . 2. Rotate the taillight socket counter -clockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. T est th e lamp for proper opera tion. 6. Reinstall all components in reverse order . F ront T urn Signal Lamp[...]

91 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. Spare fuses a re provided in a compartment on the top of the access door . 1. Open the front box cover and pull open the access door . 2. Remove the suspect fuse from the fuse panel. If the fuse is bl[...]

92 MAINTENANCE Spar k P l ug s Sp ark Plug Recommendations Refer to the specifications section beginni ng on page 1 14 for the recom- mended spark plug t ype and gap for your vehicle. T orque spark plugs to specification. Sp ark Plug Inspection Spark plug condition is i ndicative of engine operation. Check the spark plug firing end condition after [...]

93 MAINTENANCE Spar k P l ug s Sp ark Plug Removal 1. Remove the left side panel. See page 82. 2. Remove the spar k plug cap. 3. Use the spark plug wrench to remove the spark plug. T urn the plug counter- clockwise to remove it. 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. V erify that the gap is at specifica[...]

94 MAINTENANCE V ehicle Immersion If your vehicle h as been total ly submer ged in water and it's imp ossible to have it serviced before furthe r operation, perform the following pro- cedure. If the vehicle stops while fully submerge d, major engine damage ca n result if the machine is not thoroughly in spected. T ake the vehicle to you r deal[...]

95 MAINTENANCE V ehicle Immersion 7. Dry the spark plug. Reinstall the plug or install a new plug. T orque to specification. See page 92. 8. T ighten the carburetor drain screw . 9. T urn the fuel valve on. 10. Attempt to start the engine. If necessary , repeat the drying procedure. 1 1. Have the vehicle serviced by your dealer promptly , whether y[...]

96 MAINTENANCE S p ark A rrestor Occasionally , the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Pur ge the spark arrestor . Allow components to cool sufficiently before ser vic ing. The exhaust system can get extremely hot. Never run the engine in an enclo sed area or indoors. Exhaust contains poisonous [...]

97 MAINTENANCE S p ark A rrestor 6. If carbon comes out of the exhaust, cover or plug t he exhaust outlet. W ear protective gloves. 7. Lightly tap on the exhaust pipe with a rubber mallet while repeat- ing step 5. 8. If particles are still suspected to be in the muffler , elevate the rear of the vehicle 30 cm higher than the front. Block the wheels[...]

98 MAINTENANCE P VT System Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a hig h speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of balance, creating vibration and additional loads on compo nents. The PVT system rotates at high spee[...]

99 MAINTENANCE P VT System When T o Use Low Ra nge and High Range PVT Drying There may be some instances when w ate r is accidently ingested into the PVT system. Dry it out before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the drain plug. Allow the water to drain completely . Reinstall the d[...]

100 MAINTENANCE Recoil Housing (if equ ipped) Always drain the recoil ho using after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug. 1. Place the transmission in P ARK. 2. S top the engine. 3. Remove the drain screw on the bottom of th[...]

101 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosio n and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains su[...]

102 MAINTENANCE Battery Battery Removal 1. Place the transmission in P ARK. 2. Remove the seat. 3. Disconnect the battery hold-down strap. 4. Remove the battery cover (if equipped). 5. On conventional batteries, re move the battery vent tube. 6. Disconnect the black (negative) battery cable first. 7. Disconnect the red (positive) battery cable last[...]

103 MAINTENANCE Battery Battery Inst allation 1. Ensure that the battery is fully char ged. 2. Place the battery in the battery holder . 3. W ith conventional batteries, install the battery vent tube (sealed bat- teries do not have a vent tube). Th e vent tube must be free of obstructions and securely installe d. Route the tube away from the frame [...]

104 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three mo nths or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e and recharge as needed to mainta in a full charge. Battery char[...]

105 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent dama ge from leak- ing or spilled electroly te during charging. See page 102 . 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.2[...]

106 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully . 1. Check the battery voltage with a voltmeter or multimeter . A fully charged battery will register 12.8 V or higher . 2. If the voltage is less than 12.8 vo lts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 [...]

107 MAINTENANCE Cleaning and St orage W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including ins[...]

108 MAINTENANCE Cleaning and St orage W ashing the V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution. The wate r may damage components and could remove paint and labels. A void direc ting the water stream at the follow- ing items: • Wheel bearings • Radiator • T ransmission sea ls •B [...]

109 MAINTENANCE Cleaning and St orage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Cle[...]

110 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps S tarting the engine during the storage period will disturb the protective film created by fogging and damage could occur . Neve r start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Se e page 107. St abilize the Fuel 1[...]

111 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Fluid Levels Inspect the fluid levels. Change fluids as recommende d in the Periodic Maintenance Chart beginn ing on page 57. • Demand drive unit (front gearcase) • T ransmission • Rear gearcase (if equipped) • Brake fluid (change every two years and any time the fluid loo ks dark or co[...]

112 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Inspect and Lubricate Inspect all cables and lu bricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 57. Battery Storage See pages 104-105 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely su pport the veh[...]

113 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in P ARK. 3. Secure the fuel cap, oil cap and seat. 4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the Polaris vehicle to the transporting unit securely with suitable str[...]

114 SPECIFICA TIONS * Based on EU Directive 76/ 432/EC Sportsman 500 HO International Gross V ehicle W eight 1200 lbs. (544 kg) Maximum W eight Capacity 485 lbs. (220 kg) (operator , cargo, accessories) Dry W eight 696 lbs. (316 kg) Fuel Capacity 4.25 gal. (16 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2.7 qts. (2.5 l) Demand Drive Flui[...]

115 SPECIFICA TIONS Jetting Chart Clutching Sportsman 500 HO International Driving System T ype Aut omatic PVT (Pola ris V ariable T ransmission) Front Suspension MacPherson st rut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 9.5" (24 cm) travel Shift T ype Side Lever (H/L/N/R/P) Gear Reduction, Low 23.91:1 Gear Reductio[...]

116 POLARIS PRODUCTS Part Number Description Engine Lubri cant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Syntheti c 0W-40 (4-Cycle) Engine Oil (.95 l) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (3.8 l) Gearcase / T r ansmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubri cant (.95 l) 2873603 Premium AGL Syntheti[...]

117 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 26). Driving at low RPM or speed (5-1 1 km/h) Drive at a higher speed or us e low range more frequently . Insufficient warm[...]

118 TROUBLESHOOTING Engine Does Not Rotate Engine Rot ates, Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breake r Reset th e breaker Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cau[...]

119 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plug(s) [...]

120 TROUBLESHOOTING Engine Stop s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and repl ac e (if equipped) Overuse of choke Inspect , clea n and/or replace spark plugs W ater is present in fuel Replace with f[...]

121 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542-0500 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN DIRECTIVES TEST / [...]

122 W ARRANTY LIMITED W ARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED W ARRANTY on all components of th e Polaris vehicle against defects in material or workmans hip. This warranty covers the parts and labor charges for repair or replacement of defective parts which are cove red by this warranty . This[...]

123 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIE S Warranty does not apply to pa rts exposed to friction surfaces, stresses, environmental conditions and/or contaminati on, for which they were not designed or not intended, including but not limited to the following items: W arranty applies to the product only and does not allow for coverage o[...]

124 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIE S This warranty does not cover the use of unauthor ized lubricants, chemic als, or fuels that are not compatible with the vehicle. The ex clusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of an y defective materials, or components or p[...]

125 MAINTENANCE LOG Present this section of your ma nual to your dealer each ti me you r vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE KILOMETER S OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

126 MAINTENANCE LOG DA TE KILOMETER S OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

127 MAINTENANCE LOG DA TE KILOMETER S OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

128 INDEX A Accessories . . . . . . . . . . . . . . . . . . 112 Age Restrictions . . . . . . . . . . . . . . . . . 5 Air Filte r . . . . . . . . . . . . . . . . . . . . . 86 All Wheel Drive Swit ch. . . . . . . . . . 36 All Wheel Drive System . . . . . . . . . 44 B Battery . . . . . . . . . . . . . . . . . . 101-106 Charging (Conventional) . . . . [...]

129 INDEX H Handlebar Adjustme nt . . . . . . . . . . . 81 Hauling Cargo . . . . . . . . . . . . . . . 32-33 Hazard Warning Sw itch . . . . . . . . . . 36 Headlight Beam Adjustment . . . . . . . 88 Headlight Lamp . . . . . . . . . . . . . . . . 89 Helmet . . . . . . . . . . . . . . . . . . . . . . . . 16 High Range Use . . . . . . . . . . . . . . .[...]

130 INDEX S Safety Trai ning . . . . . . . . . . . . . . . . . 5 Service Interval Programming . . . . . 50 Severe Use . . . . . . . . . . . . . . . . . . . . 57 Side Panel Removal . . . . . . . . . . . . . 82 Sidehilling . . . . . . . . . . . . . . . . . . . . 24 Signal Words . . . . . . . . . . . . . . . . . . . 4 Spark Arrestor . . . . . . . . . [...]