Polaris Sportsman 9922551 manual

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. Owner's Manual for Maintenance and Safet y 2010 P antone 426c Spor tsman 500 Touring International[...]

P antone 426c For your nearest Polaris dealer , visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 U.S.A. Part No. 9922551 Rev 01 Printed in U.S.A. GB D E F I FI P S Before you operate or ride this vehicle, read the owner ’ s manual. Lesen Sie die Bedienungsanleitung, bevor Sie dieses Fahrzeug bedienen oder fahre[...]

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

1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly pro duce 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[...]

2 POLARIS, THE W A Y OUT and SPOR TSMAN ar e registered trademarks of Pol aris 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 compo nents, some minor discr[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety ale rt symbol indicates a potential personal injury ha zard. W ARN ING A W ARNING indi cates a hazard[...]

5 INTRODUCTION Failure to follow the warni ngs in this manual can result i n serious injury or death . This Polaris vehi cle is n ot a toy and can be hazardo us to operate. A collision or rollover can occur q uickly , even duri ng routine maneuvers, if you fail to take proper precaution s. Read and understand your owner's manual and all warnin[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key number 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 yo ur key number) and matin g it with one of your existing keys. The ignition switch[...]

7 SAFETY Failure to ope rate the vehicle properly can result in a collision , loss of control, accident or overturn, which may result in serious inju ry or death. Heed all safety warnings outlined in this section of the owne r ’s manual. See th e OPERA TION section of the owner ’s manual for proper operating procedures. Equipment Modifications [...]

8 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 na da bear a U.S. Department of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE ma[...]

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 goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equ i pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make s[...]

10 SAFETY Rider Safety Read and understand all warnings, cautions and operatin g procedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instructio n. T ake a training course. Beginners should re ceive training from a certified instructor . Contact an authorized Polaris deale r or v[...]

11 SAFETY Rider Safety Always wear an approved helmet that fits properly . Wear eye protection (goggles o r face shield), gloves, boots, long sleeves a nd long pan ts . Never consum e alcohol or dr ugs before or while operating this vehicle. Never operate at excessive speeds. T ravel an d turn at speeds appropriate for the terrain, visibility , ope[...]

12 SAFETY Rider Safety Keep both h ands on the handlebars. Keep both feet on the footrests. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator . Always travel slowly when operating on unfamiliar terrai[...]

13 SAFETY Rider Safety Always follow the procedures outlined in this ma nual for driving on hills. See page 46. Neve r operate on hills too steep for the ve hicle or for your abilities. Practice on smaller hills before attempti ng larger hills. Avoid climbing hills steeper than 15 ° . Always follow the procedures outlined in this manual for drivin[...]

14 SAFETY Rider Safety Always follow the procedures outlined in this manual for operating over obstacles. See p age 55. Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Alwa ys avoid skidding or sliding. See page 54. Always follow the procedures outlined in this manual for driving [...]

15 SAFETY Rider Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify the vehicle through improper installation or use o f accessories. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instr[...]

16 SAFETY Rider Safety Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control. Av oid sudden turns or swift movement of the handlebars. Always remove the ignition key when the vehicle i s not in use to preve nt unauthorized use o r acciden tal starting. Always unlock the steering before st[...]

17 SAFETY Safety Decals and Locations W arning decals have been pl aced on the vehicle for yo ur protection. Read and follow the instructions on each decal carefully . If a decal becomes illegible or comes of f, contact your Polaris dealer to purchase a replacement. Replacement sa fety decals are provided by Polaris at no charge. The part number is[...]

18 SAFETY Safety Decals and Locations Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT 5 (3 4.5) REAR 5 (34.5) MAXIMUM WEIGHT CAP ACITY 568 LBS. (258 kg) INCLUDES WEIGHT OF OPERA T OR, P ASSENGER, CARGO AND ACCESSORIES. Read Owner's Manual for more detailed loading information . Reverse Ov erride Alert Pushing reverse override button[...]

19 SAFETY Safety Decals and Locations Rack W arning, F ront and Rear W ARNING W ARNING - DO NOT TOW FROM RACK OR BUMPER. V ehicle damage or tipover may result causing severe injury or dea th. T ow only from tow hooks or hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg) Clutch Cover Alert NO STEP[...]

20 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 32. T o gain additional power whil e opera ting in reverse, press the override switch before opening th e throttle. This will canc el the reverse speed limit function. Tip : The override swi[...]

21 FEA TURES AND CONTROLS Switches Main K ey Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. S tart 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 rin g to the main switch. I[...]

22 FEA TURES AND CONTROLS Switches 4X4 Switch Use the 4X4 switch to en gage 4X4 or 2X4. See pag e 30. 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 emer gency or other situation requiring caution. 4X4 Switch Tu r n Indicators Hazard Wa rning Swi[...]

23 FEA TURES AND CONTROLS Switches T urn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also flash. Return the toggle to the center position and push it inward to end the signal. Horn Switch Press the horn switch to sound the horn. Horn Switch T urn Signal Swi[...]

24 FEA TURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle move- ment. Release the lever to reduce engine speed and vehicle move- ment. Failure to check or ma intain proper operati on of the throttle system can result in an accident if the thrott le lever sticks during opera tion. Check the lever for prop[...]

25 FEA TURES AND CONTROLS Fo o t B r a k e The all-wheel foot brake is located on the ri ght 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 br[...]

26 FEA TURES AND CONTROLS Pa r k i n g B r a k e Locking the P arking Brake 1. Place the transmission in P ARK. 2. Squeeze the brake lever toward the handlebar . 3. Push the parking brake lock forward to engage the lock. Release the brake lever . 4. T o release the parking brake lock, squeeze and release the brake lever . Operating the vehicle whil[...]

27 FEA TURES AND CONTROLS Recoil Starter (if equipped) If the battery is too weak to start the engine, use the recoil starter . Follow the starting procedu res on page 39, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil star ter rope handle tightly . 2. Pull slightly until the st arter mechanism engag[...]

28 FEA TURES AND CONTROLS Steering Lock Lock the steering to prevent unau- thorized use or th eft of the vehicle. 1. T urn the handlebars to the full right position. Tip : The hand lebars may also be locked in the full lef t position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key . Place the steering lock keys in a safe p[...]

29 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selec tor is located on the right side of the vehicle. 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 P ARK. NOTICE: Shifting gears [...]

30 FEA TURES AND CONTROLS All Wheel Dri ve (4X4) System 4X4 When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be on. When in 4X4, th e demand drive unit will automatically engage any time the rear wheels lose tr action. When the rear wheels regain traction, the demand drive unit will aut om[...]

31 FEA TURES AND CONTROLS All Wheel Dri ve (4X4) System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. T here is no limit to the length of time the vehicle may remain in 4X4. If the switch is turned of f wh[...]

32 FEA TURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission. The instrument cluster measures distanc e in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 1 1-14 km/h. Refer to page 20 for add[...]

33 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 illu minate, a battery over -voltage may have occurred and the instrument cluster may have shut of f to protect the el[...]

34 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle thro ugh the mode op tions. The reve rse override button is also the MODE button. See page 20. Tip : The tran smission cann ot be in re verse when using this fe ature. Odometer Mode The odometer records the miles or k ilometers travele[...]

35 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 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 [...]

36 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Pr ogrammable service inte rval When the ho urs of engine operatio n equal the programmed serv ice interval setting, the wr ench icon will flash for 5 seconds each time the engine is started. When this featur e is enabled, it provides a convenient reminder to perf[...]

37 OPERA TION Break-In P e riod The break-in p eriod for your new Polaris vehicle is the first ten hou rs of operation, or the time it takes to use the first two full ta nks of gaso line. No single action on your part will in crease the life an d per formance of your vehicle more tha n following the procedures for a pro per break-in. Careful treatm[...]

38 OPERA TION Pre-Ride Checklist Item Remarks P age Hand brake/lever travel Ensure proper operation 81 Foot brake Ensure proper operation 81 Brake fluid Ensure proper level 81 P assenge r seat latch Ensure latch is secure 29 F ront suspension Inspect, lubricate if necessary 65 Rear suspension Inspect, lubricate if nece ssary 65 Steering/steering lo[...]

39 OPERA TION Starting 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. Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operatin g. 1. Positi[...]

40 OPERA TION Starting the Engine 8. Move the engine stop switch to RUN. Do not press the throttle while starting the engine. 9. T urn the ignition key past the POSITION LIGHTS ON position to engage the starter . Ac tivate the starter for a m axi- mum of five seconds, releasing the key when the engine starts. 10. If the engine does not start, relea[...]

41 OPERA TION Cold W eather Operation Internal engine condensation in creases as outside tempe ratures decrease. If the vehicle is used ye ar-round, check the oil level fre- quently . A rising oil level could indi cate condensation in the bottom of the oil tank, which can lead to en gine damage. Any condensation must be drained. Always operate the [...]

42 OPERA TION Driving Procedures 1. W ear protectiv e riding gear . See page 8. 2. Perform the pre-ride inspection. See page 38. 3. Place the transmission in P ARK. 4. Mount the vehicle from the left side. 5. Sit upright. Keep your fe et on th e footrests. Keep both hands on the handlebars. 6. S tart the engine and allow it to warm up. 7. Apply the[...]

43 OPERA TION T urning the V ehicle 1. Before turning, activate a turn sig- nal to alert others of your inten- tions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. S teer in the direction of the turn, leaning your u pper body to the inside of the turn while support- ing your weight on th e outer foot[...]

44 OPERA TION Driving with a P assenger Never allow anyone un der 16 years of age to operate this vehicle. Never allow anyone un der 12 years of age to ride as a passenger on this 2-up ve hicle. Never carry more than o ne passenger on this 2-up vehicle. 1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach t[...]

45 OPERA TION Driving with a P assenger 6. Mount the vehicle from the left side. 7. After the operator is seated, the passenger should mount the vehicle from the left side. Allow a passenger to ride only in the ap proved passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. Th e passenger should n[...]

46 OPERA TION Driving Uphill Whenever traveling uphill, follow these precautions: 1. A void steep hills (15 ° maximum). 2. A void hills with sli ppery or loose surfaces. 3. Keep both feet on the footrests . 4. Shift body weight uph ill. 5. Drive straight uphill. 6. Proceed at a steady rate of speed to avoid stalling. 7. Be alert. Be prepared to ta[...]

47 OPERA TION Driving Uphill If all forwar d 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. 1. Apply the brakes gradu ally . 2. When fully stopped, loc k the hydraulic parking brake. 3. A passenger sho uld dismount first.The [...]

48 OPERA TION Driving on a Sidehill (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 sli ppery or loose surfaces. 3. A void crossing the sides of steep hills. 4. Do not cross a hillside with a p assenger on board. Ask the passenger[...]

49 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void hills with slippery or loose surfaces. 2. Never drive downhill at high speed. Slow down. 3. Drive straight downhill. A void driving downhill at an angle, which can cause the vehicle to pitch sharply to one side. 4. Shift your weight rearward . 5. Apply the bra[...]

50 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 the vehicle. Keep your weight uphill. 2. Lock the hydrau lic parking brake. 3. Leave the transmission in forw ard gear . T urn the engine of f. 4. A passenger should d ismount first.Th[...]

51 OPERA TION T urning Around on a Hill (K - T urn) 8. Lock the hydraulic parking brake. 9. Remount from the uphill side. Keep your weight uphi ll. A passenger should not r emount until the veh icle r eturns to level gr ound. 10. Apply the foot brake. 1 1. W ith the transmission still in forward, start the engine. 12. Squeeze and release the brake [...]

52 OPERA TION Driving Through W ater Follow these procedures wh en driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual in clines. 3. Drive slowly . A v oid rocks and obstacles. 4. A void operating in water deeper than the bottom of the footrests. If it's unavoidable, trave[...]

53 OPERA TION 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 pa ge 98. Have the vehicle serviced by your dealer promptly . Always follow the procedures outlined in this manual for driving through water . Never drive through deep or fas[...]

54 OPERA TION Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down b efore driving onto slippery surfaces. 2. Engage 4X4 b efore wheels begin to lose traction. 3. Be alert. 4. W atch the trail. 5. A void quick, sharp turns. 6. Correct a skid by tu[...]

55 OPERA TION Driving Over Obstacles 1. Always check for obstacles before operating in a new area. 2. Be alert. W atch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. A void ha zards such as logs, rocks and low branches. 5. Always have a pas senger dismo unt before oper ating over an obsta- cle. Always follow the procedure[...]

56 OPERA TION P arking 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 wh eels on the downhill side. 4. T urn the fuel valve off.[...]

57 OPERA TION Driving in Reverse Follow these precautions when operating in reve rse: 1. Always check for obstacles or peop le behind the vehicle before backing. Be aware that a passenge r can obstruct your view . 2. A void backing downhill. 3. Drive slowly . Apply the brak es lightly for stopping. 4. A void turning at sharp ang les. 5. Never open [...]

58 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to w ing cargo i mproperly ca n alter vehicl e handling and may cause loss of control or brake instability . Always follo w these precautions when hauli ng cargo. • Read and unde rstand the load distribution warn ings listed on the vehicle warning labe ls. • Never exceed the s[...]

59 OPERA TION Hauling Cargo T owing Loads T owing is approved OFF-ROAD ONL Y . T owing a trailer on pu blic roads is prohibited. See your Polari s dealer ab out configuring the vehi- cle to be certified to tow a trailer on-road. Do not tow any trailer on a grade steeper than 15 ° . Always attach a towed load to the hitch point. If towing a load, r[...]

60 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 requirements. Spark Arrestor Y our Polaris vehicle has a spark arrestor tha t was designed for on-road and of f-road operation. It is required that this spark ar restor re[...]

61 MAINTENANCE P eriodic Maintenance Chart Maintena nce intervals in the followin g chart are b ased upon average 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 32. R[...]

62 MAINTENANCE P eriodic Maintenance Chart Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service Q Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a Q coul d result in component failure an d lead to serious injury or d[...]

63 MAINTENANCE P eriodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Kilometers X E Air filter , main element - Weekly - Inspect; replace as needed Recoil housing (if equipped) - Weekly - Drain water as needed, check often if operating in wet conditions X Q Brake pad wear 10 Monthly 160 Inspect periodi[...]

64 MAINTENANCE P eriodic 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 Kilometers Q E V alve clearance 100 12 M 1600 Inspect; adjust Q E F ue[...]

65 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart be ginning on page 61. Items not listed in the chart should be lubr icated at the General Lubrication interval. Tip : The a-arms and upp er control arms ar e lubricated at th e factory , and no additional lubricati on will[...]

66 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's r[...]

67 MAINTENANCE Engine Oil Oil Level 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 30 seconds. 4. S top the engine. 5. Remove the dipstick. W ipe it dry with a clean cloth. 6. Reinstall the dipstick completely . 7. Remove the dipstick and ch eck the oil level. Add oil as ne[...]

68 MAINTENANCE Engine Oil Oil and Filter Change Hot oil may result in serious burns. Do not all ow 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 30 seconds. 4. S top the engine. 5. Clean the area around the drain plug. 6. Place a drain pan under th[...]

69 MAINTENANCE Engine Oil Oil and Filter Change 1 1. Disconnect the lower oil deliv- ery hos e and remove the screen fitting from the oil tank. Clean the fitting. Tip : The fitting threads 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 t[...]

70 MAINTENANCE Engine Oil Oil and Filter Change 20. Remov e the dipstic k. 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 71. 25. S top the engine. Check for oil leaks. 26. Check t[...]

71 MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must b e performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit. 2. S tart th[...]

72 MAINTENANCE T ransmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 120 for the p art numbers of Polari s products. T ransmission Oil Recommendations T ransmission Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. 4. C[...]

73 MAINTENANCE T ransmission Oil T ransmission 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 orque to specification. See page 72. 8. Add the recomme nded oil. See [...]

74 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Recommendations Use the recommended fl uid. Use of other fluids may result in improper operation of components. See page 120 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. P[...]

75 MAINTENANCE F ront Gearcase (Demand 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 74. 7. Add the reco mmended flu[...]

76 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 [...]

77 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 radia tor pressure cap. 4. If coolant is not visible, slowly add coolant through the radiator filler neck. 5. Reinstall the pressur[...]

78 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at th e recommended lev el. Do not overfil l. The brakes should feel firm when they're applied. Spongy or weak brakes may i ndicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are wo rn a[...]

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

80 MAINTENANCE Brake Fluid F oot Brake The foot brak e fluid reservoir is located under the front box. T he brake fluid reservoir cap is black. 1. Position the vehicle on a level surface. 2. Open the front box cover . 3. Open the access door . 4. V iew the fluid level in the reservoir . 5. Remove the cap and add the recommended fluid as needed. NOT[...]

81 MAINTENANCE Brakes The front and rear brakes are h ydraulic disc brakes, activated by apply- ing the foot brake . The handlebar br ake is also hydra ulic. Both brake systems are self-adjusting. Brake Inspections Perform the following chec ks to keep the brake systems in good operat- ing condition . Check more often if brak es are used heavily un[...]

82 MAINTENANCE T oe Alignment Do not attempt to adjust ali gnment. All steering ad justments should be performed by an authorized Polaris deal er . 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 ha ndlebars in a straigh[...]

83 MAINTENANCE Handlebar Adjustment The handlebars can be adjusted for rider preference. Improper adjustment of th e handlebars or inco rrect torquing of the adjuster block tig htening bolts can cause li mited steering or loosen in g of the ha ndlebars, resulting in loss of control. Follow the adjustment procedures exactly , or see your Polaris dea[...]

84 MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and b olts are found, see your Pola ris dealer for service before operating the vehicle. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or [...]

85 MAINTENANCE Side P anel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. W ith a firm moti on, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it. 5. When reinstalling side panels, align the fasteners and pres s firmly to secure them. F oo[...]

86 MAINTENANCE Throttle Cable F reeplay 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 slide it far enough to expose 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 [...]

87 MAINTENANCE Tires Operating your veh icle with worn tires, im properly infl ated tires, non-standard tires or impro perly installed tires will affect vehicle handling an d could cause an accident. • Maintain proper tire pressure as described on th e label on your vehicle and in the specifications sectio n of the owner's manual. • Use on[...]

88 MAINTENANCE Tires Wheel Nut T orque Sp ecifications Check the wheel nut torques occasional ly and when they 've been loos- ened for maintenance service. Nut T ype Nut T orque Lug Nut 122 Nm 2-Piece F lange N ut 37 Nm Cast Aluminum Steel 122 Nm 37 Nm[...]

89 MAINTENANCE Tires Always use original equipment size and type when replacing ti res. Install wheels properly . Wheel Removal/Installation 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 ground[...]

90 MAINTENANCE Air Filter Always clean and replace the air and br eather filters at the intervals out- lined in the Periodic Maintena nce Chart b eginning on page 61. 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[...]

91 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 85. 2. Remove the hose clamps from the filter and pull the fil ter 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. Repl[...]

92 MAINTENANCE Lights High 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 cente r of the headlight and make a mark on the wall at the[...]

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

94 MAINTENANCE Lights T aillight Lamp Replacement 1. Place the transmission in PA R K . 2. Rotate the taillight socket counterclockwise 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 operatio n. 6. Reinstall all components in reverse order . F ront T urn Signal Lamp Re[...]

95 MAINTENANCE F use Replacement If the engine stops or will not start, or if you experience other electrical fail- ures, a fuse may need replacement. Tip : S pare fuses are provided in a compart- ment on the top of the access door . 1. Open the front box cover . 2. Open the access door . 3. Remove the suspect fuse from the fuse panel. Install a ne[...]

96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section begi nning on page 1 18 for the recom- mended spark plug type and gap for your v ehicle. T o rque spark plugs t o specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operat ion. Check the spark plug firing end condition after the[...]

97 MAINTENANCE Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 85. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Tu r n t h e p l u g counterclockwise to remove it. 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. V erify that the gap is at specificati[...]

98 MAINTENANCE V ehicle Immersion If your vehi cle has been to tally 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 eng ine damage can re sult if the machine is not thoroughl y inspected. T ake the vehicle to your deal[...]

99 MAINTENANCE V ehicle Immersion 5. Loosen the carburetor drain screw . 6. T urn the ignition key past the POSITION LIGHTS position to engage the starter . Engage the starter for only 2-3 seconds. 7. Dry the spark plug. Reinstall the plug or install a new plug. 8. T orque to specification. See page 96. 9. T ighten the carburetor drain screw . 10. [...]

100 MAINTENANCE Carburetor Y our Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher . Above 1800 meters the engine air/fuel mixture becomes too rich and the engine lo ses approximately 3% of its powe r for each 300 meter incr ease in elevat[...]

101 MAINTENANCE Recoil Hous ing (if equipp ed) Always drain the recoil housing after operating the vehicle in wet conditions. Drain the housin g before storing the vehicle. Make su re 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 [...]

102 MAINTENANCE Spark Arrestor Failure to heed the followi ng warnings while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any comb ustible materials fro m the area. W ear eye protect ion and leather work gloves. Do not stand behind or in front of the vehicle wh ile purging. [...]

103 MAINTENANCE Spark Arrestor 6. If carbon comes out of the exhaust, cover o r plug the 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 muf fler , elevate the rear of the vehicle 30 cm higher than the front. Block the wheels.[...]

104 MAINTENANCE PVT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce i ts strength so that a failure ma y occur at a high speed. The PVT system ha s been precision balanced. Any modi fication will cause the system to be out of bal[...]

105 MAINTENANCE PVT System PVT Drying There may be some instance s when wate 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 . Rein- stall the drain plug. 4. S tart the engine. 5. A[...]

106 MAINTENANCE Battery Improperly connecting or discon necting battery cables can resul t in an explosion and cause serious injury or death. When removing the battery , always disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisono us. It contains [...]

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

108 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ge d, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recha rge as needed to mainta in a full char ge . Battery ch[...]

109 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled ele ctrolyte during cha rging. See page 107. 2. Char ge the battery with a charging output no lar ger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the spec ific grav- ity to 1[...]

110 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully . 1. Check the battery voltage with a volt meter or multimeter . A fully charged batt ery 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.[...]

111 MAINTENANCE Cleaning and Storage W ash ing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, includ[...]

112 MAINTENANCE Cleaning and Storage W ashing th e V ehicle If a high pressure water system is u sed for clea ning (not recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A v oid direc ting the water stream at the follow- ing items: • Wheel bearin gs • Radiator • T ransmission seals ?[...]

113 MAINTENANCE Cleaning and Storage 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. Tip : Chrome wheels exposed to ro ad salt (or salt in the air in coast al areas) are more susceptible to corrosion if not properly clean[...]

114 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: S tarting the engine durin g the storage perio d will disturb the protective film created by fogging and damage could occur . Never start the engine during the stora ge period. Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. See page 1 1 1. Stabilize the [...]

115 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the flu id levels. Add or change flui ds as recommended in th e Periodic Maintenance Char t beginni ng on page 61. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change every two years and any time the fluid looks dark o[...]

116 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables a nd lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 61. Battery Storage See pages 108-109 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely su pport the vehicle[...]

117 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. T urn the fuel valve off. 5. Remove the key to prevent loss during transporting. 6. Always tie the frame of the vehicle to the transporting unit secur[...]

118 SPECIFICA TIONS * Based on EU Directiv e 76/432/EC SPORTSMAN 500 T ouring International Maximum W eigh t Capacity 568 lbs. ( 258 kg) (includes operator , passenger , cargo, accessories) Dry W eight 791 lbs. (359 kg) Front Rack/S torage Box Capacity 90 lbs. (41 kg) Rear Rack Capacity 180 lbs. (82 kg) Receiver Hitch T ongue Capacity 120 lbs. ( 54[...]

119 SPECIFICA TIONS Clutching (EBS Models) *EBS models require no helix/spring adjustment Jetting Chart SPORTSMAN 500 T ouring International 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 8.75" (22 cm) tr avel T ransmiss[...]

120 POLARIS PRODUCTS Pa r t Number De scription Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS P erformance Synt hetic 2W -50 4-Cycle Oil (.95 l) 2876245 PS-4 PLUS P erformance Synthetic 2W -50 4-Cycle Oil (3.8 l) Gearcase / T ransmis sion Lubricants 2873602 Pre mium AGL Synthetic Gearcase Lubrica nt (.95 l) 2873603 Pre mi[...]

121 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high rang e Use low range. Starting out going up a steep in cline Use low range or turn around using the K-turn (see page 50). Driving at l ow RPM or ground speed (5-1 1 kmh) Drive at a higher speed or use low range more frequently . Insuffici[...]

122 TROUBLESHOOTING Engine Does Not Rotate Engine Rotates, F ails to Start Engine Backfires Possible Cause Solution Low battery voltage Rechar ge 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 Cause Solution Out of fuel Refuel Clogged fuel v[...]

123 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recomme nded 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)[...]

124 TROUBLESHOOTING Engine Stops or Loses P ower 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 ace (if equipped) Overuse of chok e Inspect , clea n and/or replace spark p lugs W ater is prese nt in fuel Replace with[...]

125 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 7 63-542-0500 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 /[...]

126 W A RRANTY 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 workmanship. Thi s warranty covers the parts and labor char ges for repair or replacement of defe ctive parts w hich are cove red by this warranty . [...]

127 W ARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND REMEDIE S The Polaris l imited warranty exc ludes any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This wa rranty also does not c over any ve[...]

128 W A RRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIE S This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su rface imperfect ions caused by external stress, heat, col d or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensat [...]

129 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE TWO YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRES S W ARRANTIES NOT ST A T ED IN THIS W A RRANTY . Some states do not allow limi- tations on how[...]

130 MAINTENANCE LOG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE KIL OMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

131 MAINTENANCE LOG DA TE KIL OMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

132 INDEX 0-9 4X4 System . . . . . . . . . . . . . . . . . 30-31 A Accessories . . . . . . . . . . . . . . . . . . 116 Age Restrict ions. . . . . . . . . . . . . . . . . 5 Air Filt er . . . . . . . . . . . . . . . . . . . . . 90 All Wh eel Drive S witch. . . . . . . . . . 22 All Wheel Drive Syst em . . . . . . . 30-31 B Battery . . . . . . . . . . [...]

133 INDEX F Fluid Recommendations Deman d Drive . . . . . . . . . . . . . . 74 Engine Oil . . . . . . . . . . . . . . . . . 66 Transm ission . . . . . . . . . . . . . . . 72 Foot Brake . . . . . . . . . . . . . . . . . . . . . 25 Footwell Removal . . . . . . . . . . . . . . . 85 Front Gearcase Fluid . . . . . . . . . . 74-75 Fuel Filt er . . . . . [...]

134 INDEX P Polaris Pro duct List . . . . . . . . . . . . 120 Polishing the Vehicle . . . . . . . . . . . 112 Position Lig ht Lamp . . . . . . . . . . . . 93 Pre-Ride Checklist . . . . . . . . . . . . . . 38 PVT Break-In. . . . . . . . . . . . . . . . . . 37 PVT Operation . . . . . . . . . . . . . . . . . 41 PVT System . . . . . . . . . . . . . . .[...]