Polaris Sportsman 500 H.O. manual

PMS 419 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 Spor tsman 400 H.O. Spor tsman 500 H.O.[...]

A card containi ng importan t A TV safety information should be attach ed to the owner's manua l on the next page. If you cannot locate this card, or if it has be en removed, pl ease call 1-800- 342-3764 for assist ance. W ARNING The engine exh au st fr om this prod u ct co ntains chem ical s known to the S tate of California to cause ca ncer [...]

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

For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922803 Rev 0  Printed in USA PMS 419 *9922803 * W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without proper training or instruction.[...]

1 WELCOME Thank you for pu rchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owne rs. W e pro udly produce an excit- ing line of utility and recreational product s. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® • Low emission vehicles (LEVs) W e believe POLARI[...]

2 POLARIS, THE W A Y OUT a nd SPOR TSM AN are registere d trademarks of POLARIS Industries Inc. Copyright 2010 POLARIS Sales Inc. All information contained with in this publication is based on the latest product information at the time of publicati on. Due to constant improvements in the design and quality of production components, some minor discr[...]

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 our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal 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 vehicle s, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuver[...]

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 POLARI S key blank (using your k ey number) and mating it with one of your existi ng keys. The ignition swit[...]

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 information about the authorized A TV RiderCourse sm that is available to you and[...]

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 injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a POLARIS vehicle, always wear a helmet that meets or excee ds estab- lished safety standards. Approved helmets in t[...]

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 or use a shatterproof helmet face sh ield. POLARIS recommends wearing approved Personal Protective Equipm ent (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make sur[...]

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 the 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 g asoline. • 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 o n pavement. A TV tires are designed for o ff-road use. If it's unavo[...]

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. Nev[...]

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 ll s as de scri b ed in the own e r 's manual. NOTE: A special technique i s required when braking while traveling down- hill. See page 53. • Always descen[...]

16 SAFETY Safety W arnings St alling While Climbing a Hill S talling, roll ing ba ckwards 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 . W hen it's safe to proc[...]

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 unavoidable to enter water that exceeds the recommended maximum depth (see page 55): • T ra[...]

20 SAFETY Safety W arnings Operating on Frozen Bodies of W ater Operating on frozen bodie s of water may re sult in seri ous inju ry or death if the A TV and/or the operator fall through the ice. Never operate the A T V on a frozen body of water unless you have indepen- dently verified that the ice is sufficiently thick to support the weight and mo[...]

21 SAFETY Safety Decals and Locations W arning labels have been placed on the vehicle for your p rotection. Read and follow the instructions on each label carefully . If 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 graphi[...]

22 SAFETY Safety Decals and Locations Tire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading can cause lo ss of co ntrol. 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 ar[...]

23 SAFETY Safety Decals and Locations Age 16 W arning W ARNING Operating this A TV if yo u are under the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under age 16. 7175551 Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch gu ard. T o prevent serious i njury , do not operate veh[...]

24 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limiter sys tem. T o gain 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 ou[...]

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 braking, 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 ra ting the vehicle. Squeeze the brake lever toward the handlebar to apply the fro nt an d re[...]

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 could 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 a[...]

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 Never back down a hill. Applying the auxi liary brake when backing down a hill may cause rear tipover , which could re sult in serious injury or death. Use caution when ap plying the auxiliary brake. Do not aggressivel y apply the auxiliary brake when going forward. The rear wheels may skid and slid e [...]

31 FEA TURES AND CONTROLS Fuel V alve The fuel valve is located under the electrical acces s pa nel. OFF: For vehicle storage and when transporting. ON: For normal operation. Choke The choke assists in s tarting a cold engine. Refer to the engine starting procedure on page 46 fo r correct choke and throttle settings during starting. Fuel Filter The[...]

32 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park T o shift gears, brake to a com- plete stop. When the engine is idling, move the lever to the desired gear . NOTICE: Shifting gears with the engin e speed [...]

33 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The All Whee l Drive sy stem is controlled by the A W D 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 T V 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[...]

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 veh icle 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 optio ns. The 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 miles travel ed 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 mov e- ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn 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 ntro l, 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 PO LARIS A TV is the first ten hours [...]

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 vehicle . 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 loc al riding club or local of ficials. 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 Page Brake system/lever travel Ensure proper operation 27 78 Brake fluid Ensure prop[...]

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. Turn 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 sta r ts . NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before opera[...]

48 OPERA TION Driving Procedures 1. W ear 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 o f travel. 6. Release the parking brake. 7. Slow[...]

49 OPERA TION T urning the V ehicle 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 turn[...]

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 wh[...]

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 while keeping body weight uphil l. 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 throu gh water with a maximum recom- mended depth eq ua l 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 operati[...]

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 ang les. 6. Never open the throttle suddenly . 7. Do not use the override button un[...]

58 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or to wing cargo imp roperly 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 capaci- ties specified for your A T V 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 lo w as possi ble. When operating ov er rough or hilly terrain, re duce speed and c[...]

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 of f.[...]

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 quali-[...]

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 ten a nc e ch art. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the[...]

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 dealer perform these services. Maintenance Chart Key  Perform these operations more of ten for vehicles subjec[...]

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

65 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km)  General lubrication 50 H 3 M 500 (800) Lubricate a ll fittings, pivots, cables, etc. Carburetor float bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage  E Throttle Cable/ ETC Switch 50 H 6 M 500 (80[...]

66 MAINTENANCE Periodic Maintenance Chart  Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service  Have an authorized POL ARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km)  Clutches (drive and driven) 100 H 12 M 1000 (1 600)[...]

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 Always change the oil filter whenever changing oil. POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W -50 4-cycle oil or a si milar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W -50 oil. Follow the manufactur er's re[...]

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 plug hole threads. See page 1 17 for the part numbers of POLARIS products. The fill plug is located on the left si de of the A TV , under th[...]

74 MAINTENANCE T ransmission Oil Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearca se. Remove the drain plug. Allow the oil to drain completely . 3. Clean and reinstall the drain plug. T orque to specification. 4. Add the prop er amount of the recommended oil. 5. Reinstall the fill plug. T orque to specification. 6. Check fo[...]

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 (hea ted) excess coolant is forced out of the [...]

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 check ed periodically for loose nuts and bolts. If loose nu ts and bolts are found, see yo ur POLARIS dealer for service before operating the vehicle. 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 i nflated 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 follo w all tire maintenance procedures as outlined in this manual a nd on the labels on the vehicle. Al ways[...]

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-filte r in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new mai[...]

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 replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a co mpartment on the top of the access door . 1. Remove the fron t box/rac[...]

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 . Always make sure lights are adjusted properly for best visibility . Headlight Lamp Replacement When servicing a halog en lamp, don[...]

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 pag e 1 18 for the recom- mended spark plug t ype and gap for yo ur vehicle. T orque spark plugs to 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 requirements. As engine speed increases, the force exerted on the movable drive sheave by the fly- weights also increases. This, in tu rn, increases the amount of pinch applied to the drive belt. Similarly , if the engine speed d[...]

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 (if equipped). 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[...]

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 an d 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 t e du ring 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 1.2[...]

102 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. St ate of Charge V oltage Action Charge T ime (Using constant current charger @ standa rd amps specifie d on to p o f ba t t er y) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None require[...]

103 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock abs orber spring is adjus ted 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 perfor- mance at altitudes ranging from zero to 6,000 feet (1800 m) and temper- atures of +40 degrees F . (4 degrees C.) or higher . Above 6000 feet (1800 m) the engine air/fuel mixture be com es overly rich and the engine loses approximately 3% of its power for [...]

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 clea n will not only improve its appear- ance but it can also extend the life of various components . NOTICE: High water pressure may d amage components. POLARIS recommends washing the vehicle by han d or with a garden hose, using mild soap. Certain products, [...]

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 v oid direc ting the water stream at the follow- ing items: • Wheel bearings • Radiator • T ransmission seals •[...]

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. Clean chr[...]

109 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps 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. Se e page 106. Stabilize t[...]

110 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Fluid Levels Inspect the fluid levels. Add or change fluids as recommended 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 Ti ps Inspect and Lubricate Inspect all cables and lubricate al l a reas 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 w[...]

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 t[...]

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 hi gher sp eed or us e low range more frequentl[...]

114 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breaker or blown fus e Reset the breaker /Re plac e fuse Low battery voltage Recharge th e battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec [...]

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 Part Number Description Engine Lubr icant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Perfo rma nce Synt he t ic 2W-5 0 4-C y c le Oil (qt.) 2876245 PS-4 PLUS Performance Syn thetic 2W-50 4-Cycle Oil (gal.) Gearcase / T ransmission Lubricants 2878068 AGL PLUS T ransmission Fluid (qt./.95 l) 2878069 AGL PLUS T r an sm[...]

118 SPECIFICA TIONS * Based on EU Directive 76/432/EC SPORTSMAN 400/500 H.O . Gross V ehicle W eight 1200 lbs. (544 kg) Maximum W eight Capacity 450 lbs. (204 kg) (operator , cargo, accessories) Dry W eight 688 lbs. (312 kg) (400) / 696 lbs. (316 kg) ( 500) Fuel Capacity 4.25 gal. (16 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmission Oil Capa cit[...]

119 SPECIFICA TIONS Jetting Chart Clutching Chart SPORTSMAN 400/500 H.O . Shift T ype Side Lever (H/L/N/R/P) Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, Forward 10.57:1 Drive Ratio, Front 3.82:1 T i res/Pressure, Front 25x8-12 / 5 psi (34.5 kPa) (400/500) T i res/Pressure, Rear 2 5x10-12 / 5 psi (34.5 kPa) (400) 25x1[...]

120 DECLARA TION OF CONFORMITY POLARIS Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 April 22, 2010 W e, POLARIS Industries Inc., declar e that the vehi cles listed below conform to the essential health and safety requirem ents applicable to off-ro ad all-terrai n vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEA[...]

121 W ARRANTY LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of the POLARIS All T e rrain V ehicle (A TV) against defe cts in material o r workmanshi p. POLARIS also gives a one year limited warranty on the final drive chai n (if equipped) for failure due to defects. Th[...]

122 W ARRANTY W A RRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANT IES AND REMEDIES The POLARIS limited warranty ex cludes any failur es that are not caused by a defe ct 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 T [...]

123 W ARRANTY LIMIT A TIONS OF W ARRANT IES AND REMEDIES This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su r face imperfect ions caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or alti tude compensati[...]

124 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY P ERIOD. POLARIS FUR THER DISCLAIMS ALL EXP RESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some states do not allow lim i- 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 V ICE 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 receiv ed authorization for expo rt from POLARIS Industries. De[...]

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 citizen, to be kept and used outside of the country in which the vehicle was origin ally purchased, all wa rranty cover age will be denied. Y ou must nonetheless warranty re gister your vehicle under your name and [...]

127 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions li mited warranty i s in addition t o the POLARIS standa rd limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this e missions-certified ve hicle is designed, built and equi pped so it conforms with applicable U.S. Envi[...]

128 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive remedy for breac h of this limi ted warranty shall be, at the excl usive option of POLARIS, repair or replacement of any defectiv e materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH O F [...]

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 / COMMENTS[...]

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

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 G Gasoline Ha ndling . . . . . . . . . . . . . . 11 Gear Selector . . . . . . . . . . . . . . . . . . 32 Gloves . . . . . . . . . . . . . . . . . . . . . . . . 9 H Hand Brake . . . . . . . . . . . . . . . . . . . 78 Handlebar Adjustme nt . . . . . . . . . . 103 Hauling Cargo . . . . . . . . . . . . . . . 58-59 Headlight Housing Replacemen[...]

133 INDEX S Safe Opera tion Practice s . . . . . . . . . . 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 . . . . . . . . . . . . [...]