Polaris Sportsman 500 HO International Owner's Manual
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Polaris Sportsman 500 HO International Owner's Manual

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  • Page 2 FOLLOW ALL INSTRUCTIONS AND WARNINGS. Pantone 425 C NEVER CARRY NEVER USE PASSENGERS WITH DRUGS OR ALCOHOL For your nearest Polaris dealer, visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A. Part No. 9922553 Rev 02 Printed in U.S.A.
  • Page 3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory motorcycles Always follow the instructions and recommendations in this manual.
  • Page 4 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 5: Table Of Contents

    Specifications ......114 Polaris Products..... . . 116 Troubleshooting .

  • Page 6: Introduction

    The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

  • Page 7: Safety Training

    Failure to follow the warnings in this manual can result in serious injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

  • Page 8: Vehicle Identification Numbers

    Record your vehicle's identification 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 your key number) and mating it with one of your existing keys.

  • Page 9: Safety

    Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com. Never permit others to operate the vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

  • Page 10: Safety

    SAFETY Operator Safety Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.
  • Page 11 SAFETY Operator Safety Always inspect your Polaris vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 53. Keep both hands on the handlebars. Keep your feet on the footrests.

  • Page 12: Operator Safety

    SAFETY Operator Safety If the vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems. Never operate on hills too steep for the vehicle or for your abilities.
  • Page 13 SAFETY Operator Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 26. Always follow the procedures outlined in this manual for operating over obstacles.
  • Page 14 See page 31. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify this Polaris vehicle through improper installation or use of accessories. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached.
  • Page 15 Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. For more information about safety, contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com.

  • Page 16: General Alert

    Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge.

  • Page 17: Tire Pressure/Load Alert

    SAFETY Safety Labels and Locations Rack Clutch Rack Warning Cover Alert Warning “No Passenger” Warning Tire Pressure/ Load Alert “No Passenger” Warning WARNING - NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING...

  • Page 18: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Gloves Sleeves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 19: Eye Protection

    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 shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.

  • Page 20: Driving Safely

    SAFETY Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 2. Apply the brakes. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.

  • Page 21: Turning The Vehicle

    Driving Safely Turning the Vehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Acti- vate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the...

  • Page 22: Driving On Slippery Surfaces

    Driving Safely 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 before driving onto slippery surfaces. 2. Engage AWD before wheels begin to lose traction. 3.

  • Page 23: Driving Over Obstacles

    Driving Safely Driving Over Obstacles 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. Watch the terrain. Use extra caution. 3.

  • Page 24: Driving Uphill

    SAFETY Driving Safely Driving Uphill 25° Maximum Whenever traveling uphill, follow these precautions: 1. Avoid steep hills (25° maximum). 2. Check the terrain carefully. 3. Avoid hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill. 6.
  • Page 25 SAFETY Driving Safely Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. Apply the brakes gradually. When fully stopped, lock the hydraulic parking brake.
  • Page 26 SAFETY Driving Safely Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with excessively slippery or loose surfaces. 3. Shift your weight uphill. 4.

  • Page 27: Driving Downhill

    Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Check the terrain carefully. 2. Avoid hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.
  • Page 28 SAFETY Driving Safely Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Lock the hydraulic parking brake. 3.
  • Page 29 Driving Safely Turning Around on a Hill (K-Turn) 8. Lock the hydraulic parking brake. 9. Remount from the uphill side. Keep your weight uphill. 10. Apply the foot brake. 11. With the transmission still in forward, start the engine. 12. Squeeze and release the brake lever to release the parking brake. 13.

  • Page 30: Driving Through Water

    SAFETY Driving Safely Driving Through Water Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements.
  • Page 31 SAFETY Driving Safely Driving Through Water If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 94. Have the vehicle serviced by your dealer promptly. If water has been ingested into the transmission (PVT), follow the pro- cedure on page 99.

  • Page 32: Parking On An Incline

    SAFETY Driving Safely Parking on an Incline Avoid parking on an incline. If it's unavoidable, follow these precau- tions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Always block the rear wheels on the downhill side. 4. Turn the fuel valve off.

  • Page 33: Driving In Reverse

    Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Always check for obsta- cles or people behind the vehicle before backing. 3. Drive slowly. 4. Apply the foot brake lightly for stopping. 5.

  • Page 34: Hauling Cargo

    SAFETY Driving Safely Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the vehicle warning labels.

  • Page 35: Towing Loads

    Never install a hitch longer than 17 cm. Never install automotive accessories on your Polaris vehicle. Always install Polaris-approved (or equivalent) accessories designed for use on the vehicle.

  • Page 36: Features And Controls

    FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Hazard Warning Switch Headlight All Wheel Drive Switch Switch Engine Stop Switch Main Key Switch Choke Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 45. To gain additional power while operating in reverse, press the override switch before opening the throttle.

  • Page 37: Main Key Switch

    Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position.

  • Page 38: Turn Signal Switch

    FEATURES AND CONTROLS Switches All Wheel Drive Switch See page 44 for all wheel drive information. Hazard Warning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.

  • Page 39: Throttle Lever

    FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.

  • Page 40: Foot Brake

    FEATURES AND CONTROLS Foot Brake The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes. If the rear wheels begin to skid Foot Brake or slide while using the foot brake, reduce brake pressure.

  • Page 41: Parking Brake

    Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze the brake lever toward the handlebar. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5. To release the parking brake lock, squeeze and release the brake lever.

  • Page 42: Steering Lock

    Steering Lock Lock the steering to prevent unau- thorized use or theft of the vehicle. Tip: Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 1. Turn the handlebars to the full left position.

  • Page 43: Fuel Tank Cap

    FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to Fuel Tank add fuel to the fuel tank. Use either leaded or unleaded gaso- line with a minimum pump octane of 87. Do not use fuel with ethanol content greater than 10%, such as E-85 fuel.

  • Page 44: Transmission Gear Selector

    FEATURES AND CONTROLS Transmission Gear Selector The transmission gear Gear Selector selector 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 PARK.
  • Page 45 FEATURES AND CONTROLS Recoil Starter (if equipped) If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 54, cranking the engine with the recoil Handle starter instead of the main key switch.
  • Page 46 FEATURES AND CONTROLS All Wheel Drive (AWD) System The AWD switch may be turned on or off while the vehicle is moving. AWD will not engage until engine speed is below 3100 RPM. AWD remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in AWD.

  • Page 47: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation.

  • Page 48: Rider Information Center

    If this occurs, take the vehicle to your Polaris dealer for proper diag- nosis. 1. Gear Indicator - This...
  • Page 49 Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 34. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the vehicle.

  • Page 50: Diagnostic Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
  • Page 51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).
  • Page 52 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference.

  • Page 53: Operation

    Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • Use extreme caution whenever handling gasoline. • Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area. • Never fill a fuel container while it's on the vehicle. Static electricity between the rack and container could cause a spark.

  • Page 54: Break-In Period

    OPERATION Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and performance of your vehicle more than following the procedures for a proper break-in.

  • Page 55: Pre-Ride Checklist

    Ensure proper operation Adjust for best side/rear vision Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles, and...

  • Page 56: Starting The Engine

    OPERATION 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. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.

  • Page 57: Cold Weather Operation

    Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

  • Page 58: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

  • Page 59: Maintenance

    MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 45. Record maintenance and service in the Maintenance Log beginning on page 125.

  • Page 60: Maintenance

    Improperly performing the procedures marked with a component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use.
  • Page 61 (if equipped) Transmission oil Engine breather filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Pre-Ride Pre-Ride Pre-Ride Pre-Ride...
  • Page 62 Periodic Maintenance Chart Item Engine oil change (break-in) General lubrication Shift linkage Steering Front suspension Rear suspension Carburetor float bowl Throttle Cable/ ETC Switch Choke cable E Carburetor air intake ducts/flange Drive belt Cooling system Engine oil change Oil filter change Oil tank vent hose (if equipped) Valve clearance...
  • Page 63 Spark arrestor Toe adjustment Brakes Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Hours Calendar Kilometers 12 M 1600...

  • Page 64: Lubrication Guide

    Item Engine Oil Brake Fluid Transmission Oil Front Demand Drive Unit (Front Gearcase) Front Prop Shaft Yoke Lube Polaris Premium 4 Synthetic 0W-40 DOT 4 Only Polaris AGL Synthetic Gearcase Lube Demand Drive Plus Fluid Polaris Premium U-Joint Lube Front Prop Shaft Yoke Method See page 63.

  • Page 65: Engine Oil

    See page 116 for the part numbers of Polaris products. Oil may need to be changed more frequently if Polaris Premium 4 oil is not used. Follow the manufacturer's recommendations for ambient tem- perature operation.

  • Page 66: Oil Level

    Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Remove the dipstick. Wipe it dry with a clean cloth.

  • Page 67: Oil Change

    Engine Oil Oil Change Hot oil may result in serious burns. Do not allow hot oil to contact skin. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for two minutes.
  • Page 68 MAINTENANCE Engine Oil Oil Change 11. Disconnect the lower oil deliv- ery hose and remove the screen fitting from the oil tank. Clean the fitting. 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 threads.
  • Page 69 Engine Oil Oil Change 20. Remove the dipstick. 21. Add 1.9 liters of recommended oil. If the sump is not drained, add about 1.6 liters initially. 22. Reinstall the dipstick. 23. Place the transmission in PARK. 24. Prime the oil pump using the procedure on page 68.

  • Page 70: Oil Pump Priming

    MAINTENANCE Engine Oil Oil Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

  • Page 71: Transmission Oil

    Transmission Oil Maintain the oil level at the bottom of the fill plug hole. Use the recommended oil. See page 116 for the part numbers of Polaris products. Oil Recommendations Lubricant Premium AGL Synthetic Gearcase Lubricant Oil Level 1. Position the vehicle on a level surface.
  • Page 72 Transmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug.

  • Page 73: Fluid Level

    Use the recommended fluid. Fill Plug Use of other fluids may result in improper operation of components. See page 116 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole Fill Level threads. Drain Plug Fluid Level 1.

  • Page 74: Fluid Change

    Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. Drain the fluid into a drain pan. 5. Clean the drain plug. 6.
  • Page 75 Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient opera- tion. Optional jets, available from your Polaris dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.)

  • Page 76: Cooling System

    Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is premixed and ready to use. Do not dilute with water. See page 116 for the part num- bers of Polaris products.

  • Page 77: Radiator Coolant

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

  • Page 78: Brake Fluid

    Never operate the vehicle with spongy-feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 116 for the part numbers of Polaris products. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
  • Page 79 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.
  • Page 80 MAINTENANCE Brake Fluid Foot Brake 1. Position the vehicle on a level surface. 2. Remove the seat. 3. View the fluid level in the master cylinder. 4. Maintain the fluid level between the minimum and maximum marks. Do not overfill. Maximum Minimum...

  • Page 81: Brake Inspections

    Brakes The front and rear brakes are hydraulic disc brakes, activated by apply- ing the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition.

  • Page 82: Toe Alignment

    2-3 mm more than the front measurement on each side of the vehicle to obtain the recommended 3-6 mm toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your Polaris dealer for ser- vice. Stand...

  • Page 83: Handlebar Adjustment

    Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Handlebar Adjustment The handlebars can be adjusted for rider preference.

  • Page 84: Side Panel Removal

    Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it.

  • Page 85: Throttle Cable Freeplay

    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 slide it far enough to expose the end of the inline cable adjuster. 3.

  • Page 86: Tire Tread Depth

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loos- ened for maintenance service.
  • Page 87 Tires Wheel Removal/Installation Always use original equipment size and type when replacing tires. Install wheels properly. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground.

  • Page 88: Air Filter

    MAINTENANCE Air Filter Always clean and replace the air and breather filters at the intervals out- lined in the Periodic Maintenance Chart beginning on page 57. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.
  • Page 89 Breather Filter/Hose The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 82. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3.

  • Page 90: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 91 Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.
  • Page 92 MAINTENANCE Lights Taillight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counter-clockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6.

  • Page 93: Fuse Replacement

    Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover and pull open the access door.

  • Page 94: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 114 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition New Spark Plug Previously Installed Spark Plug Spark Plug Inspection Spark plug condition is indicative of engine operation.
  • Page 95 Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 82. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Turn the plug counter- clockwise to remove it. 4. Inspect the electrodes for wear and carbon buildup.

  • Page 96: Vehicle Immersion

    MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following pro- cedure. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected.
  • Page 97 Vehicle Immersion 7. Dry the spark plug. Reinstall the plug or install a new plug. Torque to specification. See page 92. 8. Tighten the carburetor drain screw. 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure.

  • Page 98: Spark Arrestor

    MAINTENANCE Spark Arrestor Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor. Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors. Exhaust contains poisonous carbon monoxide gas.
  • Page 99 Spark Arrestor 6. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves. 7. Lightly tap on the exhaust pipe with a rubber mallet while repeat- ing step 5. 8. If particles are still suspected to be in the muffler, elevate the rear of the vehicle 30 cm higher than the front.

  • Page 100: Pvt System

    • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 101: Pvt Drying

    PVT System When To Use Low Range and High Range Operating at speeds less than 11 km/h Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 11 km/h PVT Drying There may be some instances when water is accidently ingested into the PVT system.
  • Page 102 Recoil Housing (if equipped) Always drain the recoil housing after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug. 1. Place the transmission in PARK. 2.

  • Page 103: Battery Maintenance

    Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion 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. WARNING Battery electrolyte is poisonous.

  • Page 104: Battery Removal

    Battery Battery Removal 1. Place the transmission in PARK. 2. Remove the seat. 3. Disconnect the battery hold-down strap. 4. Remove the battery cover (if equipped). 5. On conventional batteries, remove the battery vent tube. 6. Disconnect the black (negative) battery cable first. 7.

  • Page 105: Battery Installation

    Battery Battery Installation 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed bat- teries do not have a vent tube). The vent tube must be free of obstructions and securely installed.

  • Page 106: Battery Storage

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge.
  • Page 107 Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 102. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 108 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

  • Page 109: Cleaning And Storage

    Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.

  • Page 110: Polishing The Vehicle

    Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 111 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. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 112: Storage Tips

    107. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

  • Page 113: Fluid Levels

    Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil. 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 114 2. Be sure the storage area is well ventilated. 3. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 115: Transporting The Vehicle

    4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the Polaris vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets.

  • Page 116: Specifications

    Sportsman 500 HO International Gross Vehicle Weight Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity 90 lbs. (41 kg) Rear Rack/Storage Box Capacity Receiver Hitch Tongue Capacity...

  • Page 117: Jetting Chart

    Sportsman 500 HO International Driving System Type Front Suspension Rear Suspension Shift Type Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster...

  • Page 118: Polaris Products

    2872348 Chain Lube, Aerosol (473 ml) 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2872893 Engine Degreaser 2871956 Loctite 2871076 Polaris Battery Tender Engine Lubricant Coolant Grease / Specialized Lubricants Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 119: Troubleshooting

    Dry out the PVT. See page 99. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Always warm up the belt by operating below 48 km/h for 1.6 km.
  • Page 120 Replace with fresh recommended fuel Turn the fuel valve on Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark plugs...
  • Page 121 Add or change fuel, clean the fuel system Replace with recommended fuel Replace filter Inspect and replace (if equipped) Replace with recommended fuel See your Polaris dealer Solution Replace with lower octane fuel Inspect, clean and/or replace spark plugs Allow engine to warm up before operat-...

  • Page 122: Engine Overheating

    Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Overuse of choke Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel...

  • Page 123: Declaration Of Conformity

    Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES 98/37/EC as amended (Machinery Directive)

  • Page 124: Warranty

    WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
  • Page 125 LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination, for which they were not designed or not intended, including but not limited to the following items: • Wheels and tires •...
  • Page 126 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.

  • Page 127: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE KILOMETERS TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 128 MAINTENANCE LOG DATE KILOMETERS TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 129 MAINTENANCE LOG DATE KILOMETERS TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 130: Index

    INDEX Accessories ....112 Age Restrictions....5 Air Filter .
  • Page 131 Parking on an Incline ... . 30 Periodic Maintenance Chart ..57-61 Polaris Product List... . . 116 Polishing the Vehicle ... 108 Position Light Lamp .
  • Page 132 INDEX Safety Training ....5 Service Interval Programming..50 Severe Use ....57 Side Panel Removal.

This manual is also suitable for:

Sportsman 99225532010 sportsman 500 ho international

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