The provided context only mentions a master cylinder located on the left handlebar for the front brake. It does not specify a separate rear brake master cylinder or its location.

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Summary of Contents for Polaris Sportsman 500 X2 2007

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) • Quadricycles • RANGER utility vehicles •...
Page 4 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2006 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 ......122 Polaris Products..... . . 124 Troubleshooting .
Page 7: Know Your Vehicle
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 8: Safety
SAFETY Rider Safety 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, on your vehicle or in this manual, alerts you to the potential for injury.
Page 9: Safety Training
Failure to follow the warnings in this manual can result in serious injury or death. A Polaris Quadricycle 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 10 Never operate a Quadricycle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or call Polaris at 1-800-342-3764. Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.
Page 11 SAFETY Rider Safety Never allow a passenger to ride in the cargo box. 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 a Quadricycle.
Page 12 SAFETY Rider Safety Always inspect your Quadricycle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 43. Keep both hands 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...
Page 13 SAFETY Rider Safety If a Quadricycle 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. Always follow the procedures outlined in this manual for driving on hills.
Page 14 SAFETY Rider 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 54. Always follow the procedures outlined in this manual for operating over obstacles.
Page 15 SAFETY Rider Safety Always follow the procedures outlined in this manual for driving in reverse. See page 61. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify a Quadricycle through improper installation or use of accessories.
Page 16 Always unlock the steering before starting the engine. See page 26. 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 Quadricycle safety, call Polaris at 1-800-342-3764.
Page 17: General Alert
Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
Page 18: Tire Pressure/Load Alert
SAFETY Safety Decals and Locations Reverse Override Alert Front Rack Warning Clutch Warning Cover Alert Tire Pressure/ Load Alert Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1400 LBS.
Page 19: Box Warning
SAFETY Safety Decals and Locations Box Warning WARNING Remove flammable material containers from box before filling. WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Maximum Box Load - 348 lbs. (158 kg) Clutch Cover Alert NO STEP Front Rack Warning...
Page 20: 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 21: 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 22: Features And Controls
FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Engine Stop Switch Hazard Switch Headlight All Wheel Drive Switch Switch Horn Switch Main Key Turn Signal Switch Switch Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 32. To gain additional power while operating in reverse, press the override switch before opening the throttle.
Page 23: Light Switch
FEATURES AND CONTROLS Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position.
Page 24: All Wheel Drive Switch
FEATURES AND CONTROLS Switches All Wheel Drive Switch AWD Switch See page 28 for switch opera- tion procedures. Hazard Warning Switch 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...
Page 25: Throttle Lever
FEATURES 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. WARNING Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.
Page 26 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 or slide while using the foot Foot Brake brake, reduce brake pressure.
Page 27: Parking Brake
FEATURES AND CONTROLS 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. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever.
Page 28: Steering Lock
FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unau- thorized use or theft of the vehicle. 1. Turn the handlebars to the full right position. NOTE: The handlebars may also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise.
Page 29 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector Gear is located on the right side of Selector 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 30 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 Switch time the vehicle may remain in...
Page 31 FEATURES AND CONTROLS All Wheel Drive (AWD) System When the AWD switch is on, the Quadricycle is in four- wheel drive and the differential is locked, providing maximum traction. The demand drive unit automatically engages when the rear wheels lose trac- tion.
Page 32: Passenger Seat
FEATURES AND CONTROLS Passenger Seat Always make sure the passenger seat lock-out is functioning properly before operating with a passenger. Do not operate the vehicle with the seat in the 2-up position when oper- ating without a passenger. Always return the seat to the 1-up position for single-rider operation.
Page 33: Seat Conversion
Repeat the set- up procedure. NOTE: If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service. 8. To return the vehicle to single-rider Locked operation, reverse all steps. Always...
Page 34: Instrument Cluster
FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures dis- tance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h.
Page 35: Rider Information Center
If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1. Gear Indicator - This indicator displays gear...
Page 36 FEATURES AND CONTROLS 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 20. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the Quadricycle.
Page 37 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 38 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 39 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 40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement. 1. Enter the diagnostic mode. 2. Toggle to the screen that displays either kilometers (KM) or miles (MP).
Page 41 Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 40 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
Page 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code BEGIN SEQUENCE Barometric Pressure/Manifold Air Pressure Sensor Low Barometric Pressure/Manifold Air Pressure Sensor High Air Temp Sensor Low Voltage Air Temp Sensor High Voltage Engine Coolant Temp Low Voltage Engine Coolant Temp High Voltage Throttle Position Sensor Low Throttle Position Sensor High...
Page 43: Operation
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 44: Break-In Period
OPERATION Break-In Period The break-in period for your new Polaris Quadricycle 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 perfor- mance of your Quadricycle more than following the procedures for a proper break-in.
Page 45: Pre-Ride Checklist
Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply Polaris dielec- tric grease when lamp is replaced Brake light/taillight Check operation, apply Polaris dielec- tric grease when lamp is replaced Riding gear...
Page 46: Starting The Engine
OPERATION Starting the Engine WARNING 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 operating.
Page 47: Cold Weather Operation
Any condensation must be drained. Always operate the engine long enough to reach operating temperature, which reduces condensation. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in cold weather.
Page 48: Driving Procedures
OPERATION Driving Procedures 1. Wear protective riding gear. See page 18. 2. Perform the pre-ride inspection. See page 43. 3. Place the transmission in PARK. 4. Mount the vehicle from the left side. 5. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars.
Page 49: Turning The Vehicle
OPERATION Turning the Vehicle 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. Steer in the direction of the turn, leaning your upper body to the inside of the turn while support- ing your weight on the outer foot-...
Page 50: Driving With A Passenger
OPERATION Driving with a Passenger Never allow anyone under 16 years of age to operate this vehicle. Never allow anyone under 12 years of age to ride as a passenger on this 2-up Quadricycle. Never carry more than one passenger on this 2-up Quadricycle.
Page 51 OPERATION Driving with a Passenger 6. Mount the vehicle from the left side. 7. After the operator is seated, the passenger should mount the vehicle from the left side. NOTE: Allow a passenger to ride only in the approved passenger seat with both feet on the footrests and both hands on the passenger grab han- dles at all times.
Page 52: Driving Uphill
OPERATION Driving Uphill 15° Maximum Whenever traveling uphill, follow these precautions: 1. Never operate in TURF mode while operating on a hill or other irregular terrain. See page 28. Switch out of TURF mode and into AWD mode when ascending a hill. 2.
Page 53 OPERATION 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. 1. Apply the brakes gradually. 2. When fully stopped, lock the hydraulic parking brake. 3.
Page 54 OPERATION 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 slippery or loose surfaces. 3. Avoid crossing the sides of steep hills. 4.
Page 55: Driving Downhill
OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Avoid hills with slippery or loose surfaces. 2. Never drive downhill at high speed. Slow down. 3. Drive straight downhill. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.
Page 56 OPERATION 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 57 OPERATION Turning Around on a Hill (K-Turn) 8. Lock the hydraulic parking brake. 9. Remount from the uphill side. Keep your weight uphill. NOTE: A passenger should not remount until the vehicle returns to level ground. 10. Apply the foot brake. 11.
Page 58: Driving Through Water
OPERATION Driving Through Water Maximum Depth Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. 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 59 OPERATION 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 102. Have the vehicle serviced by your dealer promptly. Always follow the procedures outlined in this manual for driving through water.
Page 60: Driving On Slippery Surfaces
OPERATION 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 61: Driving Over Obstacles
OPERATION Driving Over Obstacles 1. Always check for obstacles before operating in a new area. 2. Be alert. Watch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches. 5.
Page 62: Parking On An Incline
OPERATION 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.
Page 63 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle before backing. Be aware that a passenger can obstruct your view. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4.
Page 64: Hauling Cargo
OPERATION 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. • Never exceed the stated load capacity for this vehicle. •...
Page 65 OPERATION Hauling Cargo Always read and understand the load distribution warning labels on the vehicle. Never exceed the weight capacities specified for this vehicle. 1. Always load the cargo box with the load as far forward as possible. 2. Slow down. 3.
Page 66: Towing Loads
Hauling Cargo Towing Loads Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road. Avoid towing on inclines. Do not exceed the maximum capacities when towing. If towing a load, reduce cargo bed weight by the amount of tongue weight.
Page 67: Dumping Cargo
OPERATION Hauling Cargo Dumping Cargo 1. Position the vehicle on a level surface. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in PARK. 3. Dismount the vehicle. 4. Lower the tailgate. If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury.
Page 68: 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 69: 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 32. Record maintenance and service in the Maintenance Log beginning on page 132.
Page 70: Maintenance Chart Key
Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death.
Page 71 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Kilometers Air filter, Weekly Inspect; replace as needed main element Recoil housing Weekly Drain water as needed, check often if operating in wet conditions Brake pad wear Monthly Inspect periodically Battery...
Page 72 36 M 4800 Clean out Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services.
Page 73: Lubrication Guide
Item Lube Method Engine Oil Polaris Premium 4 Synthetic See page 72. 0W40 Brake Fluid DOT 4 Only See page 84. Transmission Oil Polaris AGL Synthetic See page 78.
Page 74: Oil Recommendations
See page 124 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 75: Oil Level
MAINTENANCE 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 76: Engine Oil
MAINTENANCE Engine Oil Oil and Filter Change CAUTION 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 30 seconds.
Page 77 MAINTENANCE Engine Oil Oil and Filter Change 11. Disconnect the lower oil deliv- ery hose and remove the screen fitting from the oil tank. Clean the fitting. NOTE: The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape. 12.
Page 78 MAINTENANCE Engine Oil Oil and Filter Change 20. Remove the dipstick. 21. Add 1.9 liters of recommended oil. NOTE: If the sump is not drained, add about 1.6 liters initially. 22. Reinstall the dipstick. 23. Place the transmission in PARK. 24.
Page 79: Oil Pump Priming
MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose connection between the oil tank and 5 cm 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 Clamp...
Page 80: Transmission Oil
MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 124 for the part numbers of Polaris products. Transmission Oil Recommendations Lubricant Oil Change Fill Plug Drain Plug...
Page 81: Transmission Oil Change
MAINTENANCE Transmission Oil Transmission 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 82: Fluid Level
Use the recommended fluid. Fill Plug Use of other fluids may result in improper operation of components. See page 124 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 83: Fluid Change
MAINTENANCE 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 84: 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 124 for the part num- bers of Polaris products.
Page 85: Radiator Coolant
MAINTENANCE Cooling System Radiator Coolant WARNING 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.
Page 86: Brake Fluid
Never operate the Quadricycle with spongy- feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 124 for the part numbers of Polaris products. WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
Page 87 MAINTENANCE Brake Fluid Hand Brake Indicator Window The master cylinder is Master Cylinder 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 Full level surface.
Page 88: Foot Brake
MAINTENANCE Brake Fluid Foot Brake 1. Position the vehicle on a level surface. 2. Open the front box cover. 3. Open the access door. 4. View the fluid level in the master cylinder. 5. Maintain the fluid level between the minimum and maximum marks.
Page 89: Brake Inspections
MAINTENANCE 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 90: Toe Alignment
Stands and rear of the front rim. Rear measure- ment should be 2-3 mm more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service.
Page 91: Handlebar Adjustment
MAINTENANCE 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 92: Side Panel Removal
MAINTENANCE 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 93: Throttle Cable Freeplay
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 slide it far enough to expose the end of the inline cable adjuster. Boot 3.
Page 94: 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 95 MAINTENANCE Tires Always use original equipment size and type when replacing tires. Install wheels properly. Wheel Removal/Installation 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 96: 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 67. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.
Page 97 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 90. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3.
Page 98: High Beam Adjustment
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 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 99 MAINTENANCE Lights WARNING 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 100 MAINTENANCE Lights Taillight Lamp Replacement 1. Place the transmission in PARK. 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. Test the lamp for proper operation. 6.
Page 101 MAINTENANCE Lights Taillight/Brakelight Lamp Replacement 1. Open the tailgate. Screws 2. Remove the two screws near the tailgate latch. 3. Grasp the entire taillight assembly and pull it away from the vehicle. 4. Remove the harness connector from the back of the light assem- bly.
Page 102: Spark Plugs
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 122 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition Torque Specification New Spark Plug 12-15 N-m Previously Installed Spark Plug 23-27 N-m Spark Plug Inspection...
Page 103 MAINTENANCE Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 90. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise to remove it. 4. Inspect the electrodes for wear and carbon buildup.
Page 104: 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 105 MAINTENANCE Vehicle Immersion 4. Turn the ignition key past the POSITION LIGHTS position to engage the starter. Engage the starter for only 2-3 seconds. 5. Dry the spark plug. Reinstall the plug or install a new plug. 6. Torque to specification. See page 100.
Page 106: Spark Arrestor
MAINTENANCE Spark Arrestor Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor. WARNING 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 107 MAINTENANCE 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 108: 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 109: Pvt Drying
MAINTENANCE PVT System PVT Drying There may be some instances when water 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 PARK. 3. Remove the drain plug. Allow the water to drain completely. Rein- stall the drain plug.
Page 110: Recoil Housing
MAINTENANCE Recoil Housing 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. Recoil Housing 1. Place the transmission in PARK. 2.
Page 111 MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Always keep battery terminals and connections free of corrosion.
Page 112: Battery Removal
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. Battery Removal 1.
Page 113: Battery Installation
MAINTENANCE 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). NOTE: The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent con- tact with electrolyte.
Page 114: Battery Storage
NOTE: 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. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
Page 115 MAINTENANCE 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 110. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
Page 116 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 117: Cleaning And Storage
MAINTENANCE 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 118: Polishing The Vehicle
• Labels and decals • Electrical components and wiring NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
Page 119 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. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
Page 120: Storage Tips
Make any necessary repairs and clean the vehicle as recommended. See page 115. 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. NOTE:...
Page 121 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 injectors should be completely drained of gasoline.
Page 122 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 123: Transporting The Vehicle
MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap and seat. 4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the Quadricycle to the transporting unit securely with suitable straps or rope.
Page 124: Specifications
Spark Plug NGK BKR6E Spark Plug Gap .035+0.0/-0.004 in. (0.9+0.0/-0.1 mm) Lubrication System Dry Sump Driving System Type Automatic PVT (Polaris Variable Transmission) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 8.75" (22 cm) travel...
Page 125 SPECIFICATIONS Sportsman 500 X2 Quadricycle Transmission Automatic EBS (Engine Braking System) w/E-Z Shift H/L/N/R/P Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, High 10.57:1 Drive Ratio, Front 3.82:1 Tires/Pressure, Front 25x8-12 / 5 psi (34.5 KPa) Tires/Pressure, Rear 25x11-12 / 5 psi (34.5 KPa) Brake, Hand All-wheel hydraulic disc...
Page 126: Polaris Products
Chain Lube, Aerosol (185 ml) 2872348 Chain Lube, Aerosol (473 ml) Additives / Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2872893 Engine Degreaser 2871956 Loctite 565 Thread Sealant 2871076 Polaris Battery Tender Charger...
Page 127: Troubleshooting
PVT system Clutch malfunction See your Polaris dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Slippage from failure to...
Page 128 Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...
Page 129 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plug(s)
Page 130: Engine Overheating
TROUBLESHOOTING Engine Stops or Loses Power 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 (if equipped) Water is present in fuel Replace with fresh recommended fuel Old or non-recommended fuel Replace with fresh recommended fuel...
Page 131: Warranty
At the time of sale, the Warranty Registration Form must be completed by your dealer At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE.
Page 132 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 Quadricycle...
Page 133 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris Quadricycles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
Page 134: 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 135 MAINTENANCE LOG DATE KILOMETERS TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
Page 136: Index
INDEX Accessories ....120 Driving on Slippery Surfaces ..58 Age Restrictions....7 Driving Over Obstacles .
Page 137: Oil Change
Horn ..... 22 Polaris Product List... . . 124 Light Switch ....21 Polishing the Vehicle .
Page 138 INDEX Taillight ..... . 98 Vehicle Identification Numbers..5 Taillight Lamp Replacement ..99 Vehicle Immersion .

Polaris Sportsman 500 X2 2007 Owner's Manual For Maintenance And Safety

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