Polaris 500 HO manual

P antone 426C Owner's Manual for Maintenance and Safet y Read this manual carefully . It contains important safety information. This is an adult vehicle only . Operation is prohibited for those under 16 years of age. Spor tsman 500 HO[...]

A card containi ng importan t A TV safety information should be attach ed to the owner's manual on the ne xt page. If you cannot locate this card, or if it has been removed, plea se call 1-800- 342-3764 for assist ance. WA R N I N G The engine exhaust from this prod uct contains chemicals known to the S tate of California to cause ca ncer , bi[...]

The text is printed on 100% recycled with 40% post-consumer waste (PCW) .[...]

P antone 426C 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 o f utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® W e believe Polaris sets a standard of excellence for[...]

2 POLARIS, THE W A Y OUT and SPOR TSMAN ar e registered trademark s of Polaris Industries 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 discre[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 24 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y ou r 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 injury ha zard. W ARNING A W ARNING indicates a hazardous[...]

5 INTRODUCTION Failure to heed the warnings and safety precautions contained in thi s manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate. Thi s vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuvers[...]

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 Safety T raining A TV safety training is a top prior ity for Polaris. Polaris strongly encourages you and any family member s who will be riding the A TV to take a training course. If you purchased a new Polaris A TV in the United States, your dealer provided instruction to y ou about the authorized A TV RiderCourse sm that is available to[...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort and to redu ce the chance of in jury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the[...]

9 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 [...]

10 SAFETY Safety W arnings Failure to operate the A TV properly can re sul t in a collision, loss of control, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’s manual. See th e OPERA TION section of the owner ’s manual for proper operating proce dures. Operating[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is highl y flammable and explosive u nder certain conditions. • Always exercise extreme caution w henever handling gasoli ne. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- el[...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicle without wea ring an approved helmet and protective eyewear increases the risk of a seri ous injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield). Using Alcohol or Drugs Oper[...]

13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the A TV and could result in loss of control and accident or overturn. Avoid operating the A TV on pavement. A TV tires are designed for o ff-road use. If it's unavoi[...]

14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the footrests during operatio n can reduce your abili ty to control th e vehicle or cause loss of balance and ejection from the A TV . If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. Neve[...]

15 SAFETY Safety W arnings Descending Hill s Improper ly Improperly descending a hill could cause loss of control or overtu rn. • Always follow proper procedures for travel- ing down hi lls as described in t he owner's manual. NOTE: A special technique i s required when braking while traveling down- hill. See page 53. • Always descend a hi[...]

16 SAFETY Safety W arnings St alling While Climbing a Hill S talling, roll ing backwards or improperly dismounting while climbing a hil l could cause an overturn. • Always maintain a steady speed whe n climbing a hill. If all forward speed is lost: • Keep body weight up hill. • Apply the brakes. • Lock the parking brake when fully stopped. [...]

17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when operati ng on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain. Always use ex tra caution on roug h, slippery or loose terrain. Op[...]

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a coll ision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 57. Before shifting into reverse gear , always check for obstacles or people behind the A TV . When it's safe to proce[...]

19 SAFETY Safety W arnings Operating Through Deep W ater Operating the A TV through deep or fast- flowing water could cause the tires to floa t, causing loss of control or overturn. Avoid operating the A TV through deep or fast-flowing water . If it's unavoidabl e to enter water that exceeds the recommended maximum depth (see page 55): • T r[...]

20 SAFETY Safety W arnings Operating on Frozen Bodies of W ater Operating on frozen bodie s of water may re sult in serious inju ry or de ath if the A TV and/or the operator fall through the ice. Never operate the A T V on a frozen body of wa ter . Poor V isibility Operating the A TV in darkness or inclement weathe r could result in a collision or [...]

21 SAFETY Safety Decals and Locations W arn ing labels have been placed on the vehicle for your protectio n. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual differ from the labels on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or graph[...]

22 SAFETY Safety Decals and Locations Tire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading can cause lo ss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa) • Maximum weight capacity: 485 lbs. (220 kg) 7175642 “No Passenger” W arn[...]

23 SAFETY Safety Decals and Locations Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch gu ard. T o p revent serious injury , do not operate vehicle wi th guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, whi ch can result in serious injury or dea[...]

24 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limiter sys tem. T o ga in additional wheel speed while backing, release the throttle and depress the override button. W ARNING! Pressing the override button whil e the throttle is open can cause loss of control, which may result in seri o[...]

25 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engi ne quickly . The engine will no t start or run whe n the switch is of f. Both the main switch and the engine stop switch will shut of f all electri- cal power to the vehicle, including lights. Main Key Switch Use the [...]

26 FEA TURES AND CONTROLS Throttle Lever Operating an A TV wi th sticking or impr operly operating throttle controls could cause an accident. Never start or oper ate an A TV that has a sticking or improperly operating throttle . Always c ontact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of th[...]

27 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of bra king, which could cause an accident. Never operat e the A TV with a spongy-fee ling brake lever . Always contact your dealer for service before ope rating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear[...]

28 FEA TURES AND CONTROLS Master Cylinde r/Brake Fluid An over-full master cyl inder may cause brake drag or brake lock-up, which co uld result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the [...]

29 FEA TURES AND CONTROLS Parking Brake Locking the P arking Brake 1. Place the transmission in PA R K . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lo ck, squeeze and release the brake lever[...]

30 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxiliary brake whe n backing down a hill may cause rear tipover , w hich could result in seri o us injury or death. Never back down a hill. Use caution when ap plying the auxiliary b rake. Do not aggressively a pply the auxiliary brake when going forward. The rear wheels may [...]

31 FEA TURES AND CONTROLS Choke The choke assists in s tarting a cold engine. Refer to the engine starting procedure on page 46 for correct ch oke and throttle settings during start- ing. Fuel V alve The fuel valve is located under the front storage box cover . OFF: For vehicle storage and when transporting. ON: For normal operation. Fuel T ank Cap[...]

32 FEA TURES AND CONTROLS Automatic 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 T o shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear . NOTICE: Shifting gears with the engine speed ab[...]

33 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The All Whee l Drive syst em is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive and the A WD indicator light in the instrument cluster will be on. When in A WD, the demand drive u[...]

34 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In ad dition to showing vehicl e speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measure s dist ance in miles as well as hours of operation. It also incl u[...]

35 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[...]

36 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle thro ug h the mode options. Th e reverse override button is also the MODE bu tton. See page 24. The transmis sion cannot be in reverse wh en using this feature. Odometer Mode The odomete r records the m iles traveled by the A TV . T ri[...]

37 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 off an d on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn the [...]

38 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[...]

39 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 servic e interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Cente[...]

40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers toggle The display in the tripmeter and od ometer can be changed to display either standard or metr ic units of measurement. 1. Enter the diagnostic mode. 2. T oggle to the screen that displays either kilometers (KM) or miles (MP). 3. Press and ho[...]

41 OPERA TION Failure to operate the A TV properly can result in a collision, loss of co ntrol, accident or overturn, which may result in serious injury or death. Rea d and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in period for yo ur new Polaris A TV is the first ten hours of[...]

42 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 31. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 69. Add oil if neces- sary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en area th[...]

43 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before operatin g this vehicle. See page 7. 2. Do not allow anyone und er 16 year s of age to operate this ve hicle. Do not allow anyone w ith cognitive or physical disabi lities to oper- ate this ve hicle. 3. Never carry a passenger on this A TV . 4. Engine exhaust[...]

44 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you ride. Fin d out where the de signated riding areas are by con- tacting your Polaris dealer , a loca l riding club or loc al officials. Help kee[...]

45 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 27 78 Brake fluid Ensure pro[...]

46 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in P ARK. 3. Lock the parking brake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. Sit on [...]

47 OPERA TION S t arting the Engine 1 1. T urn the ignition key past the ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the engin e starts. NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operati[...]

48 OPERA TION Driving Procedures 1. W ea r a helmet and eye protection. See page 8. 2. Sit upright with both feet on th e footrests and both hands on the handlebars. 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 parking brake. 7. Slow[...]

49 OPERA TION T urning the V ehic le Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly . T o turn, steer in the direc- tion of the tur[...]

50 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precaution s: 1. Do not operate on excessively ro ugh, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage A WD before wheels begin to lose traction. NOTICE: Severe[...]

51 OPERA TION Driving Uphill Braking and handling are greatly affe cted when operating in hilly ter- rain. Improper pro cedure could cau se loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Always check the terrain care fully before ascending any [...]

52 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. [...]

53 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. Shift body weight uphill. 3. Drive straight downhill. 4. Slow down. Excessive speed wh en traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually . Applying the brakes too firmly may cause the rear whe[...]

54 OPERA TION 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. S top and lock the parking brake wh ile keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hicle, or on the left[...]

55 OPERA TION Driving Through W ater Y our A TV can operate through water with a maximum recom- mended depth eq ual to the bot- tom of the footrests. Follow these procedures when operat- ing through wa ter: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks have grad ual inclines. 3. A void operating[...]

56 OPERA TION Driving Over Obst acles Follow these precautions whe n operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra cau tion when operating on unfamilia[...]

57 OPERA TION Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the bra kes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override button unl[...]

58 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or to w ing cargo impr operly can alte r vehicle handling and may cause loss of control or brake instability , which can re sult in serious injury or death. Always follo w these precaution s when hauling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO.[...]

59 OPERA TION Hauling Cargo Never exceed the weight capac- ities specified for your A TV on warning labels an d in the speci- fications section of this manual. 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 operating ov er rough or hilly terrain, re duce speed and carg[...]

60 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parking brake. 4. Always block the rear wheels on the do wnhill side. 5. T urn the fuel valve off.[...]

61 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that was tested and qualif[...]

62 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main tenance chart . Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the ne[...]

63 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked with a  could result in component failure and cause an accident, wh ich may result in se rious injury or death. Always have an authorized Pola ris de aler perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subject[...]

64 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[...]

65 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc. Carburetor float bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage Q E Throttle Cable/ ETC Switch 50 H 6 M 500 (800) In[...]

66 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 Miles (Km) Q Clutches (drive and driven) 100 H 12 M 1000 (1600) Inspect[...]

67 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 62. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will be neede[...]

68 MAINTENANCE Engine Oil Oil Recommendations Polaris Premium 4 All Season synthetic engine oil has been sp ecially formulated for use in Pola ris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil desi gned to provide t he ultimate in lubrication performance and protectio n. See page 1 17 for the part num- bers of [...]

69 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the A TV . A rising oil level between checks in cool weather driving ca n indicate contaminants such as gas or mois- ture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediat ely . 1. Position the vehicle on a[...]

70 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Star t the engine. Allow it to idle for two to three minut es. 3. S top the engine. 4. Clean the a[...]

71 MAINTENANCE Oil and Filter Change 12. Place shop towels beneath the oil filter . Using an oil filter wrench, turn the filter counter -clockwise to remove it. 13. Using a clean dry cloth, clean the filter sealing surface on the crank- case. 14. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring i[...]

72 MAINTENANCE Oil and Filter 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 or pinch of f the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure[...]

73 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 62. Maintain the oil level at the bottom of the fill pl ug hole threads. W e recommend the use of Polaris Premium AGL Synthetic Gearcase Lubrica nt. See page 1 17 for the part numbers of Polari[...]

74 MAINTENANCE T ransmission Oil Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain com- pletely . 4. Clean and reinstall the drain plug. T orque to 22 ft. lbs. (30 Nm). 5. Add 32 oz. (948 ml) of th e recommended oil. 6. Reinstall the fill plug. T orque to 22 ft. lbs. (30 Nm[...]

75 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Check 1. Position the vehicle on a level su rface. Remove the fill plug. Check the fluid level. 2. Add the recommend ed demand driv e fluid as needed to bring the level to the bottom of the fill hole threads. 3. Reinstall the fill plug. T orque to 8-10 ft. lbs. (1 1-14 Nm). Fluid Change 1. P[...]

76 MAINTENANCE Cooling System The engine coolant level is controll ed, or maintained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expa nding (heated) excess coolant is forced out of the e[...]

77 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair . If the recove[...]

78 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar . These brakes are self- adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drops. If the fluid le ve l is low and the diaphragm is not extended, a leak is lik[...]

79 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment. Do not attempt to adju st tie rod alignment. All tie rod a djustments should be perfo[...]

80 MAINTENANCE S teering Assembly The steering assembly o f the A TV should be checked periodica lly for loose nuts and bolts. If loose nu ts and bolts are found, see your Polaris dealer for service before operati ng the vehicl e. Side Panel Re moval 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull[...]

81 MAINTENANCE Ti r es Operating your A TV with worn tires, impr operly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follow all tire maintenance procedures as outlined in this manual a nd on the labels on the vehicle. Al ways u[...]

82 MAINTENANCE Ti r es Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing t oward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower the vehicle to the ground. 6. T orque the wheel [...]

83 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre- filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new main[...]

84 MAINTENANCE Breather Filter/Hose The breather filter is on the hose th at runs between the engine and air box. See illustration above. 1. Remove the left side panel. See page 80. 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[...]

85 MAINTENANCE F use Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replaceme nt. Locate and correct any short circuits that may have caused the blown fus e, then replace the fuse. Spare fuses are pro- vided in a compartment on the top of the access door . 1. Open the front box cov[...]

86 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Cl ean lights frequently and replace burn ed out lamps promptly . Alway s make sure lights are adjusted properly for best visibility . Headlight Lamp Replacement When servicing a halog en lamp, do[...]

87 MAINTENANCE Light s 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 su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall . Place the transmission in P ARK. 2. Measure the distance from the floo r to the ce[...]

88 MAINTENANCE Light s Headlight Housin g Replacement 1. Remove the two screws on the lowe r 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 disconn ect the speedometer harnes ses from the speedometer . 4. Unplug the headlamp from the wiring harness. 5. Use a s[...]

89 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headlamp . 3. Reinstall the harness assembly into the headlight assembly . 4. T urn the headlight harness clock- wise to secure th[...]

90 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations Refer to the specifications section beginni ng on page 1 18 for the recom- mended spark plug t ype and gap for your vehicle. T orque spark plugs t o specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Sp [...]

91 MAINTENANCE Spar k P l u g s Sp ark Plug Inspection Normal Spark Pl ug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and wh ite. A white insulator ti[...]

92 MAINTENANCE V ehicle Immersion If your vehicle becomes imm ersed, major engine da mage can result if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impossi ble to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the A TV to dry land or at[...]

93 MAINTENANCE S p ark Arrestor Failure to heed the following warnings whil e servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protectio n and leather work gloves. Do not stand behind or in fro nt of the vehicle while purging. Ne[...]

94 MAINTENANCE P VT System Failure to comply with the instructions in this warning can result in severe injury or death. 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 balanc[...]

95 MAINTENANCE P VT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt. Similarly , if the engine speed de[...]

96 MAINTENANCE P VT System When T o Use Low Range and High Range PVT Drying There may be some instances when wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely . Rein- stall the d[...]

97 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 sul[...]

98 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover . 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the A TV . Be careful not to tip a conven[...]

99 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructio ns on page 101 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in t[...]

100 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. Tip : Power [...]

101 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 98. 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 1.270[...]

102 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. State of Charge V oltage Action Charge Time (Using constant cu rrent charger @ standard amps specifie d on top of batt ery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-1[...]

103 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock abs orber spring is adjuste d by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your Polaris dealer . Handlebars The handlebars can be adjusted for rider [...]

104 MAINTENANCE Carburetor Y our Polaris A TV 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 60 00 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea ch[...]

105 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 1/16"[...]

106 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. NOTICE: High water pressure may damage compone nts. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, incl[...]

107 MAINTENANCE Cleaning and St orage W ash ing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The wate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: • Wheel bearings • Radiator • T ransmission seals •B[...]

108 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[...]

109 MAINTENANCE Cleaning and St orage Sto r ag e Tips NOTICE: S t arting the engine during the storage period will di sturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 106. Stabilize the[...]

110 MAINTENANCE Cleaning and St orage Sto r ag e Tips Fluid Levels Inspect the fluid levels. Add or change fluids as reco mmended in the Periodic Maintenance Char t beginning on page 62. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change every two years and any time the fluid loo ks dark[...]

111 MAINTENANCE Cleaning and St orage Sto r ag e Tips Inspect and Lubricate Inspect all cables and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 62. Battery Storage See pages 100-101 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV wit[...]

112 MAINTENANCE T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in PA R K . 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the A TV to the transporting unit securely with suitable straps or rope. Do no t attach tie straps to[...]

113 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 54). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or us e low range more frequently [...]

114 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breake r Reset t he 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 [...]

115 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) [...]

116 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 replace Overuse of choke Inspect, cl ea n and/or replace spark plugs W ater is present in fuel Replace with new fuel Fouled o[...]

117 POLARIS PRODUCTS Pa rt Number Description Engine Lubr icant 2870791 Fo gging Oil (12 oz. Aero sol) 2871281 Premium 4 Synthetic 0W -40 (4-Cycle) Engine Oil (qt./.95 l) 2871844 Premium 4 Synthetic 0W -40 (4-Cycle) Engine Oil (gal./3.8 l) Gearcase / T rans mission Lubricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) 2873603 Pre[...]

118 SPECIFICA TIONS * Based on EU Directive 76/ 432/EC Sportsman 500 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) T ransmission Oil Capa city 32 oz. (948 ml) Demand Drive Fluid Ca pa[...]

119 SPECIFICA TIONS Jetting Chart Clutching Chart Sportsman 500 Driving System T ype Automatic PVT (Polaris 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 Reduction, Reverse 16[...]

120 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 /[...]

121 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s. This warranty c[...]

122 W ARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND RE MEDIES The Polaris limi ted warranty excludes any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This warranty also does not cover any A TV t[...]

123 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND RE MEDIES This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su r face imperfections caused by external stress, heat, col d or contamination; operator error or abuse; improper component alignment, tension, adjustment or alti tude compensati[...]

124 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT N OT LIMITED TO THE IMPLIED W ARRANTIES O F MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR T HER DISCLAIMS ALL EXP RESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some st ates do not allow limi- tations on[...]

125 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries. Deal[...]

126 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private ci tizen, to be kept and used outside of the country in which the vehicle was origin ally purchased, all warrant y coverage will be denied. Notice If your vehicle is registered outside of the country where it was p[...]

127 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions li mited warranty i s in addition to t he Polaris standard limite d warranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S. Environm[...]

128 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive remedy for breac h of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REME DIES SET FOR TH IN THIS LIMITE D W ARRANTY A RE THE ONL Y REMED IES A V AILABLE T O ANY PERSON FOR BREACH [...]

129 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 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMM ENTS[...]

130 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

131 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 111 Air Filte r . . . . . . . . . . . . . . . . . . . . . . 83 All Wheel Drive System . . . . . . . . . . 33 Apparel, Prote ctive . . . . . . . . . . . . . . 12 Auxiliary Foot B rake . . . . . . . . . . . . 78 AWD Switch . . . . . . . . . . . . . . . . 24, 33 AWD System . . . . . . . . .[...]

132 INDEX F Fuel Valve . . . . . . . . . . . . . . . . . . . . 31 Fuse Replacement . . . . . . . . . . . . . . 85 G Gasoline Ha ndling . . . . . . . . . . . . . . 11 Gear Selector . . . . . . . . . . . . . . . . . . 32 Gloves . . . . . . . . . . . . . . . . . . . . . . . . 9 H Hand Brake . . . . . . . . . . . . . . . . . . . 78 Handlebar Adjustme n[...]

133 INDEX S Safe Opera tion Practices . . . . . . . . . . 43 Safety Deca ls . . . . . . . . . . . . . . . 21-23 Safety Labels "No Passenger" W arning . . . . . . . 22 Age 16 Warning . . . . . . . . . . . . . . 22 Clutch Cover Warning . . . . . . . . . 23 Discretionary Wa rning . . . . . . . . . 21 General Warning . . . . . . . . . . . . .[...]