Polaris Offroad Vehicle 500 HO International User Manual

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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.

The manual contains instructions for minor maintenance, but informa-

tion about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician. Please see your dealer for all of your service needs

during (and after) the warranty period.

For more information about Polaris, visit us online at

www.polarisindustries.com.

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-

tries Inc.

based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor discrep-

ancies may result between the actual vehicle and the information presented in this publi-

cation. Depictions and/or procedures in this publication are intended for reference use

only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse

of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

Printed in U.S.A.

2010 Sportsman 500 HO International Owner’s Manual

P/N 9922553

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls. . . . . . . . . . . . . . . . . . . 34

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Emission Control Systems . . . . . . . . . . . . . . . 56

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 114

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 116

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 117

Declaration of Conformity. . . . . . . . . . . . . . . 121

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 125

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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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.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in

minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order

to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be

taken to avoid a hazard.

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INTRODUCTION

WARNING

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.

Read and understand your owner's manual and all warnings before operating

this Polaris vehicle.

Safety Training

When you purchased your new Polaris vehicle, your dealer offered a

hands-on safety training course. You were also provided with printed

materials that explain safe operating procedures. Review this informa-

tion on a regular basis.

If you purchased a used Polaris vehicle from a party other than a Polaris

dealer, please request free safety training from any authorized Polaris

dealer.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited

for anyone under 16 years of age.

Restrictions

This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a

trailer with this vehicle on public roads is prohibited.

Equipment Modifications

The warranty on your Polaris vehicle may be terminated if any equip-

ment has been added, or if any modifications have been made, that

increase speed or power. The addition of certain accessories, including

(but not limited to) mowers, blades, tires, sprayers and large racks may

change vehicle handling. Use only Polaris-approved accessories. Know

their function and effect on the vehicle.

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INTRODUCTION

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.

The ignition switch must be replaced if all keys are lost.

VIN

Engine Serial Number

####

Key Number

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

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SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow the instructions and

procedures listed here and throughout this manual.

Read and understand all warnings,

cautions and operating procedures in

this manual and on the safety labels

before operating the vehicle.

Never operate this vehicle without

proper instruction. Take a training

course. Beginners should receive

training from a certified instructor.

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.

Never allow anyone under 16 years of

age to operate this vehicle.

Never carry a passenger. The purpose

of the long seat is to allow the operator

to shift position.

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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.

Never attempt jumps or other stunts.

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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.

Always travel slowly when operating

on unfamiliar terrain. Use extra

caution.

Use caution when operating on rough,

slippery or loose terrain.

Always follow the procedures outlined

in this manual for turning. See page

19.

Never turn sharply at excessive

speeds, which can lead to vehicle

overturn.

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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.

Practice on smaller hills before

attempting larger hills. Avoid climbing

hills steeper than 25°.

Always follow the procedures outlined

in this manual for climbing hills. See

page 22.

Always follow the procedures outlined

in this manual for driving downhill and

for braking on hills. See page 25.

Always follow the procedures outlined

in this manual for crossing the side of

a hill. See page 24.

Never attempt to turn the vehicle

around on any hill until you've

mastered (on level ground) the turning

technique outlined in this manual.

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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. See page 21.

Always follow the procedures outlined

in this manual for operating on

slippery or loose surfaces. Use extra

caution. Always avoid skidding or

sliding. See page 20.

Always follow the procedures outlined

in this manual for driving through

water. Never drive through deep or

fast-flowing water. See page 28.

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SAFETY

Operator Safety

Always follow the procedures outlined

in this manual for driving in reverse.

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. Reduce speed and follow

the instructions in this manual for

carrying cargo or towing. Allow a

greater distance for braking.

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SAFETY

Operator Safety

Never operate the vehicle on a frozen

body of water.

Operating on paved surfaces may

affect the handling and control of the

vehicle and could result in loss of

control. Avoid sudden turns or swift

movement of the handlebars.

Always remove the ignition key when

the vehicle is not in use to prevent

unauthorized use or accidental

starting.

Always unlock the steering before

starting the engine. See page 40.

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.

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SAFETY

Safety Labels and Locations

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. The part number is printed on the label.

The following pages repeat the information found on each label.

General Alert

(Multi-Lingual)

Before you operate this

vehicle, read the owner’s

manual.

General

Alert

Hill Operation Alert

• Never operate this vehicle on HILLS

Age 16

steeper than 25 degrees

25°.

Alert

• To prevent flip-over on hilly terrain,

when going up or down, use throttle

and brakes gradually.

Hill

Operation

Alert

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SAFETY

Safety Labels and Locations

Rack

Warning

Clutch

Cover Alert

Rack

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

MACHINE, DRIVER AND CARGO IS 1200 LBS. (546 kg). Read Owner's

Manual for more detailed loading information.

Clutch Cover Alert

NO STEP

Rack Warning, Front and Rear

WARNING - DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or

tipover may result causing severe injury or death. Tow only from tow hooks or

hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)

Reverse Override Alert

Pushing reverse override button may cause sudden increases in power and

traction if too much throttle is applied. Loss of control or forward flipover may

result, especially in AWD. See Owner's Manual.

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SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet

Eye Protection

Long

Sleeves

Gloves

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.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

granted approval. The approval number and serial

number will also be displayed on the label.

051039

0006.31

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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 shield. Polaris recommends wearing approved

Personal Protective Equipment (PPE) bearing markings such as VESC

8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and

protection.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs.

Riding pants with kneepads and a jersey with shoulder pads provide the

best protection.

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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. Check your surroundings and determine your path of travel.

6. Release the brakes.

7. Slowly squeeze the throttle lever toward the handlebar to begin

driving.

8. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

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SAFETY

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

outer footrest. Use the same

leaning technique for turning

in reverse.

3. Practice turning at slow speeds

before attempting to turn at faster speeds.

Never operate at excessive speeds.

Travel and turn at speeds appropriate

for the terrain, visibility, operating

conditions and your experience.

Always follow the procedures outlined

in this manual for turning. Never turn

sharply at excessive speeds, which

can lead to vehicle overturn.

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SAFETY

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. Be alert.

4. Watch the trail.

5. Avoid quick, sharp turns.

Tip: To correct a rear wheel skid,

turn the handlebars in the

same direction as the skid and shift body weight forward.

NOTICE: Severe damage to the drive train may occur if AWD is engaged while

the wheels are spinning. Engage AWD when the wheels have

traction.

Always follow the procedures outlined

in this manual for operating on

slippery or loose surfaces. Use extra

caution. Always avoid skidding or

sliding.

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SAFETY

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. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

Always follow the procedures outlined

in this manual for operating over

obstacles.

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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. Keep your feet on the footrests.

7. Drive at a steady rate of speed to avoid stalling.

8. Be alert. Be prepared to take emergency action. This may

include dismounting quickly.

9. Never open the throttle suddenly or make sudden gear changes.

10. Never go over the top of a hill at high speed.

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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. See page 39.

Dismount on the uphill side, or to either side if the vehicle is pointed

straight uphill. Turn the vehicle around using the K-Turn. See page 26.

Always follow the procedures outlined

in this manual for climbing hills. Avoid

climbing hills steeper than 25°.

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.

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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. Avoid crossing the sides of steep hills.

5. Keep your feet on the footrests.

6. Steer slightly into the hill.

7. If the vehicle begins to tip, quickly turn the front wheels downhill

(if possible) or dismount on the uphill side immediately!

Always follow the procedures outlined

in this manual for crossing the side of

a hill.

Never attempt to turn the vehicle

around on any hill until you've

mastered (on level ground) the turning

technique outlined in this manual.

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SAFETY

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. Drive straight

downhill.

6. Shift your weight rearward.

7. Apply the brakes slightly to aid in slowing.

Always follow the procedures outlined

in this manual for driving downhill and

for braking on hills.

Never operate at excessive speeds.

Travel and turn at speeds appropriate

for the terrain, visibility, operating

conditions and your experience.

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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. Leave the transmission in forward gear. Turn the engine off.

4. Dismount on the uphill side of the vehicle, or on the left if the vehi-

cle is pointing straight uphill.

5. Stay uphill of the vehicle and turn the handlebars full left.

6. Squeeze the brake lever to release the parking brake.

7. Slowly release the brake lever and allow the vehicle to roll around

to your right until it's pointing across the hill or slightly downward.

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SAFETY

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. Release the foot brake and drive slowly downhill. Control speed

with either the hand or foot brake until the vehicle is on level

ground.

Always follow the procedures outlined

in this manual for climbing hills. See

page 22.

Always follow the procedures outlined

in this manual for crossing the side of

a hill. See page 24.

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SAFETY

Driving Safely

Driving Through Water

Maximum Depth

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. Maintain a slow and steady forward

motion. Do not make sudden turns, stops or throttle changes.

3. Choose a crossing where both banks have gradual inclines.

4. Drive slowly. Avoid rocks and obstacles.

5. Wet brakes may have reduced stopping ability. Always test your

brakes after leaving water. If necessary, apply them lightly several

times to allow friction to dry out the pads.

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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.

Always follow the procedures outlined

in this manual for driving through

water. Never drive through deep or

fast-flowing water.

If the vehicle stops while fully submerged, major engine damage can result if the

machine is not thoroughly inspected. Take the vehicle to your dealer before

starting the engine.

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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.

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SAFETY

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. Avoid turning at sharp

angles.

6. Do not use the override

switch unless additional

power is required for vehicle movement. Use with caution.

Tip: Reverse speed is greatly increased when the override switch is used. Do

not operate at full throttle. Apply just enough throttle to maintain the desired

speed.

Excessive throttle operation while in the speed limit mode may cause fuel to

build in the exhaust, resulting in engine popping and/or engine damage.

Always follow the procedures outlined

in this manual for driving in reverse.

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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.

• Never exceed the stated load capacity for this vehicle.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO OR TOWING. Use extreme caution when applying

brakes. Avoid situations that require backing downhill.

• When operating over rough or hilly terrain, reduce speed, cargo and towed

load to maintain stable driving conditions.

• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on

the front rack.

• CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load

high on the rack raises the center of gravity of the vehicle and creates a less

stable operating condition. Reduce load weight when cargo is high. Secure

off-centered loads that cannot be centered and operate with extra caution.

• CARRYING A LOAD on only one rack may cause the vehicle to overturn.

Split the load between the front rack and rear rack, with 1/3 in the front and 2/

3 in the back. Do not exceed load capacities. See specifications beginning on

page 114.

• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the vehi-

cle.

• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load

and operate with extra caution. Always attach the tow load to the hitch point

designated for your vehicle.

• USE EXTREME CAUTION when operating with loads that extend over the

rack sides. Stability and maneuverability may be adversely affected, causing

the vehicle to overturn.

• TOWING is approved OFF-ROAD ONLY. Operating this vehicle with a trailer

on public roads is prohibited.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when

towing loads in rough terrain, while cornering, or while ascending or descend-

ing hills.

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SAFETY

Driving Safely

Hauling Cargo

2/3

1/3

Towing Loads

Towing is approved OFF-ROAD ONLY. Operating this vehicle with a

trailer on public roads is prohibited. Do not exceed the maximum capac-

ities when towing. Do not tow any trailer on a grade steeper than 15°.

Towing Specifications

Maximum Towed Load (Level Ground)

Maximum Towed Load (Up to 15° Grade)

Maximum Vertical Hitch Weight

557 kg

386 kg

55 kg

Using an improper hitch or exceeding the

maximum tongue weight capacity can

result in serious damage to the vehicle

and will void your warranty. 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.

Maximum

17 cm

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FEATURES AND CONTROLS

Switches

Mode/Reverse

Override Switch

Hazard Warning

Switch

Headlight

Switch

All Wheel Drive

Switch

Engine

Stop Switch

Choke

Main Key

Switch

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. This will cancel the reverse speed

limit function.

The override switch also allows activation of All Wheel Drive in

reverse, if the AWD switch is on.

Activating the override switch with the throttle open and while operating in

reverse can cause loss of control. Do not activate the override switch while the

throttle is open.

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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.

Do not attach a large key fob or key ring to the main switch. It may contact the

gas tank cap when turning, causing an interruption to the electrical system and

an unexpected engine shut-down during operation. This could result in serious

injury or death.

Engine Stop Switch

The engine will not start or run when

the switch is in the OFF position.

Engine

Stop Switch

OFF

RUN

Light Switch

Light

Switch

The lights do not operate unless the

main key switch is on and the engine

stop switch is in the RUN position.

High Beam

Low Beam

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FEATURES AND CONTROLS

Switches

All Wheel Drive Switch

See page 44 for all wheel drive

information.

AWD Switch

Hazard Warning Switch

Hazard

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.

Turn

Indicators

Turn Signal Switch

Turn Signal

Switch

Push the toggle switch

either left or right to

activate the corresponding

turn signal light. The

indicator on the pod will

also flash. Return the

toggle to the center

position and push it

inward to end the signal.

Horn Switch

Press the horn switch to

sound the horn.

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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. Check the lever for

proper operation before starting the engine. Check occasionally during

operation.

Do not start or operate a vehicle with sticking or improperly operating throttle

controls. Contact your dealer for repair if throttle problems arise.

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust

the mirrors before driving the vehicle.

Electronic Throttle Control (ETC)

ETC causes the engine to stop

if the throttle cable sticks in

an open position when the

operator releases the throttle

lever.

Electronic Throttle Control

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle

system malfunction. Do not modify the ETC system or replace it with other

throttle mechanisms.

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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

brake, reduce brake pressure.

Foot Brake

Hand Brake Lever

The hand brake operates both front

and rear brakes. Squeeze the brake

lever toward the handlebar to apply

the all-wheel brakes.

If the rear wheels begin to skid or

slide while using the brake, reduce

lever pressure.

Aggressively applying the brakes when backing down a hill may cause rear

tipover. Aggressively applying the brakes while moving forward may cause the

rear wheels to skid and result in loss of control.

Read this owner's manual and understand the operation of all brake systems on

this vehicle. Always use caution whenever applying the brakes.

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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.

4. Release the brake lever.

5. To release the parking brake

lock, squeeze and release the

brake lever.

Operating the vehicle while the parking brake is engaged could result in an

accident and serious injury or death. Always release the parking brake lock

before operating.

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FEATURES AND CONTROLS

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.

2. Insert the steering lock key

and turn it clockwise.

3. Remove the key.

4. Reverse the procedure to

unlock the steering.

The handlebars are locked in the full left position when the steering is locked.

Always unlock the steering before starting the engine.

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FEATURES AND CONTROLS

Fuel Tank Cap

Remove the fuel tank cap to

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.

Fuel Tank

Cap

Fuel Filter

The in-line fuel filter should be

replaced by your dealer after

every 100 hours of operation or

annually. Do not attempt to

clean the fuel filter.

Choke

The choke assists in starting a cold engine. Refer to the engine starting

procedure on page 54 for correct choke and throttle settings during start-

ing.

Fuel Valve

The fuel valve is located under the

front storage box cover.

OFF: For vehicle storage and when

transporting.

OFF

ON: For normal operation.

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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. The transmission

is locked when it’s in

PARK.

Shifting gears with the engine speed above idle or while the vehicle is moving

can cause transmission damage. Stop the vehicle, release the throttle and move

the shift lever to the desired gear. See your dealer if you experience any shifting

problems.

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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

starter instead of the main key

switch.

Handle

1. Grasp the recoil starter rope

handle tightly.

Recoil Starter

2. Pull slightly until the starter

mechanism engages.

3. Pull the rope abruptly to start the engine.

Extending the recoil starter rope until it stops can cause damage to the recoil

assembly. Do not extend the starter rope so far that it stops.

If the starter rope handle is not seated properly, water may enter the recoil

housing and damage components. Make sure the handle is fully seated on the

recoil housing, especially when traveling in wet areas.

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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.

If the switch is turned off while the demand drive unit is engaged, it will

not disengage until the rear wheels regain traction. Engage AWD before

getting into situations where maximum traction is needed. If the rear

wheels are spinning, release the throttle before switching to AWD.

Tip: The override switch allows activation of AWD in reverse if the AWD switch

is on. See page 34.

Switching to AWD while the rear wheels are spinning may cause severe drive

shaft and gearcase damage. Always switch to AWD while the rear wheels have

traction or are at rest.

AWD

When the AWD switch is on,

the vehicle 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. When the rear wheels

regain traction, the demand drive unit automatically disengages.

2X4

When the 2X4 switch is on,

the vehicle is in two-wheel

drive at all times and the dif-

ferential is locked.

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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. It also includes a reverse speed limiter function that limits the

vehicle's speed to approximately 11-14 km/h. Refer to page 34 for addi-

tional information.

Speedometer

Needle

Speedometer

Rider

Information

Center

High water pressure may damage vehicle components. Wash the vehicle by

hand or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the

speedometer lens and other plastic surfaces. Do not use alcohol to clean the

instrument cluster. Do not allow insect sprays to contact the lens. Immediately

clean off any gasoline that splashes on the instrument cluster.

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FEATURES 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 may have shut off to protect the electronic speedome-

ter. If this occurs, take the vehicle to your Polaris dealer for proper diag-

nosis.

1. Gear Indicator - This

indicator displays gear

shifter position:

H = High Gear

L = Low Gear

N = Neutral

R = Reverse Gear

P = Park

2. AWD Indicator - This

indicator illuminates

when the AWD switch

is in the AWD position.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Odometer/Tachometer/Tripmeter/ Hour Meter

6. Fuel Gauge - The segments of the fuel gauge show the level of fuel

in the fuel tank. When the last segment clears, a low fuel warning is

activated. All segments will flash, FUEL will display in the LCD,

and the speedometer needle will blink. Refuel immediately.

7. Check Engine Warning Indicator - The word HOT displays if the

engine overheats. Do not operate the vehicle if this warning

appears. Serious engine damage could result.

8. Mode Indicator

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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 34.

NOTE: The transmission cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

The trip meter records the miles traveled by the vehicle on each trip if

it's reset before each trip. To reset the trip meter, select the trip meter

mode. Press and hold the mode button (override button) until the total

changes to 0.

NOTE: In the Rider Information Center, the trip meter display contains a deci-

mal point, but the odometer displays without a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Tachometer Mode

The engine RPM is displayed digitally.

NOTE: Small fluctuations in the RPM from day to day may be normal because

of changes in humidity, temperature and elevation.

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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. Turn the key switch off and wait 10 seconds.

2. Lock the parking brake.

3. Place the transmission in neutral.

4. Hold the mode/reverse override button and turn the key switch on.

Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the diagnostic screens.

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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). This screen is for informa-

tional purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge. This screen is for informational purposes

only. Please see your dealer for all major repairs.

Programmable service interval

When the hours of engine operation equal the programmed service

interval setting, the wrench icon will flash for 5 seconds each time the

engine is started. When this feature is enabled, it provides a convenient

reminder to perform routine maintenance. See page 50.

The service interval is programmed at 50 hours at the factory.

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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.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for 2-3 seconds, until the wrench

icon flashes. Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours

quickly.

5. If you scroll past the intended number, press and hold the button

until the hours cycle back to zero.

6. When the desired setting is displayed, wait until the wrench icon

stops flashing. The new service interval is now programmed.

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).

3. Press and hold the mode button until the letters flash, then press and

release the button once. When the display stops flashing, the mode

has been set.

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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.

• Do not smoke or allow open flames or sparks in or near the area where refu-

eling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing.

• Turn the fuel valve off whenever the vehicle is stored or parked.

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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.

Careful treatment of a new engine and drive components will result in

more efficient performance and longer life for these components.

Do not operate at full throttle or high speeds for extended periods during

the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with the recommended fuel. See page 41.

2. Check the oil level. Add oil if necessary.

3. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

4. Drive slowly. Vary the throttle positions. Do not operate at sustained

idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 53.

6. Pull only light loads.

7. Change the oil and filter at 20 hours or one month.

PVT Break-in (Clutches/Belt)

Break in the clutches and belt by operating at slower speeds during the

break-in period as recommended. Pull only light loads. Avoid aggres-

sive acceleration and high speed operation during the break-in period.

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OPERATION

Pre-Ride Checklist

Item

Remarks

Page

Foot brake

Ensure proper operation

Ensure proper level

Hand brake/lever travel

Brake fluid

Front suspension

Rear suspension

Steering/steering lock

Inspect, lubricate if necessary

Unlock the steering; ensure free oper-

ation

Tires

Inspect condition and pressure

Wheels/fasteners

Inspect, ensure fastener tightness

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Throttle

Ensure proper operation

Indicator lights/switches

Engine stop switch

Mirrors

Ensure proper operation

Adjust for best side/rear vision

Inspect, clean

Air filter, pre-filter

Air box sediment tube

Headlamp

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light/tail lamp

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Wear approved helmet, goggles, and

protective clothing

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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. Turn the fuel valve on.

4. Sit on the vehicle.

Tip: The starter interlock will prevent the engine from starting if the transmission

is in gear and the brake is not engaged.

Tip: Do not use the choke if starting a warm engine. Excessive use of the choke

can cause the spark plug to become wet fouled.

5. If the engine is cold, pull the choke

knob out until it stops. If the knob

doesn't stay where positioned,

increase the tension by rotating the

tension adjusting nut clockwise.

Tip: The variable choke is fully on when the

knob is pulled completely out. The choke

is off when the knob is pushed completely

Tension

Adjusting Nut

in. The choke can be adjusted gradually,

depending on how much choke is needed

for starting. Be sure the choke is off during

operation, as excess fuel washing into the

engine oil will increase wear on engine components.

6. Move the engine stop

switch to RUN.

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OPERATION

Starting the Engine

7. Do not press the throttle while starting the

engine. Turn the ignition key past the

POSITION LIGHTS ON position to

engage the starter. Activate the starter for

a maximum of five seconds, releasing the

key when the engine starts.

8. If the engine does not start, release the

starter and wait five seconds.

9. Repeat steps 7 and 8 until the engine starts.

Operating the vehicle immediately after starting could cause engine damage.

Allow the engine to warm up for several minutes before operating.

10. If a warm engine has cooled to a point where it does not readily

start, intermittent use of the choke (pulled half way out) may be

necessary. If the engine is over-choked when warm, depress the

throttle lever fully while cranking to aid in starting. Release the

throttle lever immediately after the engine starts. If the engine does

not start and all conditions are favorable, change the spark plug and

try again.

11. If the engine slows or stops, position the choke knob half way in to

allow proper engine warm up. Vary the engine RPM slightly with

the throttle to aid in warm-up. When the engine idles smoothly,

push the choke completely in.

Cold Weather Operation

Internal engine condensation increases as outside temperatures

decrease. If the vehicle is used year-round, check the oil level fre-

quently. A rising oil level could indicate the accumulation of contami-

nates such as water or excess fuel in the bottom of the crankcase. Water

in the bottom of the crankcase can lead to engine damage and must be

drained. 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.

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EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so

may affect compliance with governmental noise level requirements.

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.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine

design, including factory-set fuel delivery and ignition. The engine and

related components must be maintained at Polaris specifications to

achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the

operator perform. Any other adjustments should be performed by an

authorized Polaris dealer.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/EC.

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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.

Service and adjustments are important for proper vehicle operation. If

you're not familiar with safe service and adjustment procedures, have a

qualified dealer perform these operations.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold

weather can indicate contaminants collecting in the oil sump or crank-

case. Change oil immediately if the oil level begins to rise. Monitor the

oil level, and if it continues to rise, discontinue use and determine the

cause or see your dealer.

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MAINTENANCE

Periodic Maintenance Chart

WARNING

Improperly performing the procedures marked with a „ could result in

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.

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.

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MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar Kilometers

Steering

Pre-Ride

Daily

Make adjustments as need

ed. See Pre-Ride Checklist

on page 53.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever

Foot brake

Brake system

Wheels/fasteners

Frame fasteners

X Engine oil level

X Air filter, pre-filter

Inspect; clean often; replace

as needed

X Air box sediment

Daily

Drain deposits when visible

tube

Coolant

Check level daily, change

coolant every 2 years

Headlamp/tail

lamp

Daily

Check operation; apply

dielectric grease if replacing

X Air filter,

E main element

Weekly

Inspect; replace as needed

Recoil housing

(if applicable)

Drain water as needed,

check often if operating in wet

conditions

X Brake pad wear

Monthly

160

Inspect periodically

Battery

Monthly

300

400

Check terminals; clean; test

Inspect level; change yearly

X Demand drive fluid

(front gearcase)

X Rear gearcase oil

Monthly

400

Inspect level; change yearly

(if equipped)

X Transmission oil

Monthly

400

Inspect level; change yearly

Inspect; clean if needed

X Engine breather

E filter (if equipped)

X Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar Kilometers

X Engine oil change

1 M

Perform a break-in oil change

at one month

(break-in)

X General

3 M

800

Lubricate all fittings, pivots,

cables, etc.

lubrication

Shift linkage

6 M

800

Inspect, lubricate, adjust

Lubricate

Steering

X Front suspension

Lubricate

X Rear suspension

Lubricate

Carburetor float

bowl

Drain bowl periodically and

prior to storage

Throttle Cable/

6 M

800

Inspect; adjust; lubricate;

replace if necessary

ETC Switch

Choke cable

Inspect; adjust; lubricate;

replace if necessary

E Carburetor air

Inspect duct for proper seal-

ing/air leaks

intake ducts/flange

Drive belt

Inspect; adjust; replace as

needed

Cooling system

Inspect coolant strength

seasonally; pressure test

system yearly

X Engine oil change

100

6 M

1600

Perform a break-in oil change

at one month

X Oil filter change

100

6 M

1600

Replace with oil change

Inspect routing, condition

X Oil tank vent hose

(if equipped)

Valve clearance

100

12 M

1600

Inspect; adjust

Fuel system

Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

X Fuel filter

100

12 M

1600

Replace annually

X Radiator

Inspect; clean external

surfaces

X Cooling hoses

100

12 M

1600

Inspect for leaks

Inspect

X Engine mounts

Exhaust muffler/

pipe

Inspect

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar Kilometers

Spark plug

100

12 M

1600

Inspect; replace as needed

X Wiring

100

12 M

1600

Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

100

12 M

1600

Inspect; clean; replace worn

parts

and driven)

Front wheel

bearings

Inspect; replace as needed

Brake fluid

200

300

24 M

36 M

3200

4800

Change every two years

Clean out

Spark arrestor

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Brakes

Inspect daily; adjust as

needed

Headlight aim

Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Lubrication Guide

Always check and change fluids and lubricate greaseable compo-

nents at the intervals outlined in the Periodic Maintenance Chart

beginning on page 57. Items not listed in the chart should be lubri-

cated at the General Lubrication interval.

Item

Lube

Method

Engine Oil

Polaris Premium 4 Synthetic See page 63.

0W-40

Brake Fluid

DOT 4 Only

See page 76.

See page 69.

Transmission Oil

Polaris AGL Synthetic

Gearcase Lube

Front Demand Drive

Unit (Front Gearcase)

Demand Drive Plus Fluid

See page 71.

Front Prop Shaft Yoke

Polaris Premium U-Joint

Lube

Grease fittings (3 pumps maxi-

mum) every 800 km, before long

periods of storage, or after pres-

sure washing or submerging.

Front Prop Shaft Yoke

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MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing oil.

Polaris recommends the use of Premium 4 Synthetic 0W-40 engine oil

for this engine. Premium 4 is a fully synthetic, high performance, multi-

viscosity oil designed to provide the ultimate in lubrication performance

and protection. 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.

Mixing brands or using a non-recommended oil may cause serious engine

damage. Always use a recommended oil. Never substitute or mix oil brands.

Oil Specifications

Model

Lubricant

Capacity

Drain Plug Torque

Sportsman 500 HO

International

Premium 4 Synthetic

0W-40

1.9 liters

19-23 N-m

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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.

6. Reinstall the dipstick

completely.

Dipstick

7. Remove the dipstick and check the oil level. Add oil as needed.

Maintain the oil level in the safe range. Do not overfill.

Safe Range

Add Oil

Safe

8. Reinstall the dipstick.

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MAINTENANCE

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.

4. Stop the engine.

5. Clean the area

around the drain

Screen

Fitting

plug.

Drain

Plug

6. Place a drain pan

under the oil tank.

7. Remove the drain

plug.

New Sealing Washer

8. Drain the oil.

9. Clean the drain plug. Reinstall the drain

plug with a new sealing washer.

10. Torque to specification. See page 63.

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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. Continue to rotate

the fitting until the nipple of the

fitting aligns with the mark on the tank.

Alignment Mark

Tip: Do not over-tighten. Maximum torque for the screen fitting is 34 N-m.

13. Reattach the oil line.

14. Place towels under the oil filter.

Using an oil filter wrench, turn the

filter counter-clockwise to remove it.

15. Clean the filter sealing area on the

crankcase.

16. Lubricate the filter o-ring. Check to make

sure the o-ring is in good condition.

17. Install the new oil filter. After the filter

contacts the crankcase surface, turn it 1/2

turn by hand.

18. Approximately 240 ml of engine oil will remain in the crankcase.

To drain, remove the drain plug on the lower right side of the crank-

case.

Tip: The sealing surfaces on the drain plug and crankcase should be clean and

free of burrs, nicks or scratches.

19. Reinstall the drain plug. Torque to specification.

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MAINTENANCE

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.

25. Stop the engine. Check for oil leaks.

26. Check the oil level.

Safe Range

Add oil as needed.

Maintain the oil level

in the safe range. Do

not overfill.

27. Reinstall the dipstick.

Safe

Add Oil

28. Discard used oil and

filter properly.

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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.

Tank

5 cm

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.

Clamp

Pressure

Relief Slit

2. Start the engine. Allow it to idle

for 10-20 seconds.

3. Remove the vent line clamp. If

the line is bled properly, you should hear a rush of air. If you do not

hear a rush of air, repeat the priming procedure.

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MAINTENANCE

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

Oil Change

Capacity

Fill Plug

Torque

Drain Plug

Torque

Premium AGL Synthetic

Gearcase Lubricant

948 ml

30 N-m

Oil Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Check the oil level.

Maintain the level at the

bottom of the fill hole

threads.

5. Add the recommended

oil as needed. Do not

overfill.

6. Reinstall the fill plug.

Torque to specification.

Oil Level

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MAINTENANCE

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.

7. Reinstall the drain

plug. Torque to

specification. See

page 69.

8. Add the recommended oil.

9. Reinstall the fill plug. Torque

to specification.

10. Check for leaks.

11. Discard used oil properly.

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MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Recommendations

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug

Torque

Demand Drive Demand Drive Plus Fluid

Unit

175 ml

11-14 N-m

15 N-m

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

threads.

Fill Level

Drain Plug

Fluid Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Add the recommended demand drive fluid as needed.

5. Reinstall the fill plug. Torque to specification.

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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. Reinstall the drain plug. Torque

to specification. See page 71.

7. Add the recommended fluid.

8. Reinstall the fill plug. Torque to

specification.

9. Check for leaks.

10. Discard used oil properly.

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MAINTENANCE

Carburetor

This vehicle is calibrated at the factory for optimal performance at alti-

tudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40

degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the

engine air/fuel mixture becomes overly rich and the engine loses

approximately 3% of its power for each 1000-foot (304.8 m) increase in

elevation. 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.)

Continuous operation of the engine without proper jetting when

required can cause poor performance, overheating or PVT or engine

damage. See your Polaris dealer for more information about jetting the

ATV for conditions in your area.

Pilot screws are sealed with metal plugs and are serviceable only by

Polaris dealers.

Carburetor/Engine Idle RPM Adjustment

Recommended engine idle RPM is 1200 +/- 200. If the engine idle

speed is unsatisfactory and all other conditions are favorable, the carbu-

retor can be adjusted.

1. Start the engine and allow it to

warm up for approximately five

minutes.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Turn the screw in (clockwise) to

raise RPM. Turn the screw out

(counter-clockwise) to lower RPM.

Idle Screw

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MAINTENANCE

Cooling System

Any time the cooling system has been drained for maintenance or repair,

replace the coolant with a fresh mixture of antifreeze and water. Drain

the cooling system every two years. Add fresh coolant.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool-

ant or a 50/50 mixture of high 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.

Always follow the manufacturer's mixing recommendations for the

freeze protection required in your area.

Recovery Bottle Coolant

Some coolant level drop on new machines is

normal, as the system is purging itself of trapped

air. Add coolant as needed.

Tip: Check the coolant level in the radiator any time

the recovery bottle has run dry.

1. Check the coolant level when the

fluid is cool. Maintain the coolant

level between the minimum and max-

imum marks on the bottle (when the

fluid is cool).

2. Remove the left side panel. See page

82.

3. View the coolant level.

4. Add coolant as needed.

5. Reinstall the side panel.

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MAINTENANCE

Cooling System

Radiator Coolant

Escaping steam can cause severe burns. Never remove the pressure cap while

the engine is warm or hot.

1. Open the front box cover.

2. Open the access door.

3. Remove the radiator pressure cap.

4. If coolant is not visible, slowly

add coolant through the radiator

filler neck.

5. Reinstall the pressure cap.

Tip: Use of a non-standard pressure cap

will not allow the recovery system to

function properly. Contact your dealer

for the correct replacement part.

6. Secure the access door and box

cover.

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MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride.

Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak

brakes may indicate a fluid leak or low fluid level. A low fluid level

may also mean that brake pads are worn and need to be replaced. Do not

operate the vehicle with spongy or weak brakes. See your dealer for ser-

vice.

Operating the vehicle with a spongy brake can result in loss of braking, which

could cause an accident. 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. Maintain brake fluid at the recommended level.

Do not overfill.

Under normal operation, the diaphragm extends into the reservoir as

fluid level drops. If the fluid level is low and the diaphragm is not

extended, a leak is likely and the diaphragm should be replaced. To

ensure proper diaphragm operation, always fill the reservoir as needed

whenever the cover is loosened or removed. Do not overfill.

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,

meaning it rapidly absorbs moisture from the air. The moisture causes the

boiling temperature of the brake fluid to drop, which can lead to early brake fade

and the possibility of accident or severe injury. After opening a bottle of brake

fluid, always discard any unused portion.

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MAINTENANCE

Brake Fluid

Hand Brake

Indicator

Window

Master

Cylinder

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.

Full

2. View the fluid level

through the indicator win-

dow (eye) on the top of the

master cylinder.

Low

Tip: The eye will appear dark when

the fluid level is full. When fluid

is low, the eye will be clear.

3. Add the recommended

fluid as needed. Do not overfill.

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MAINTENANCE

Brake Fluid

Foot Brake

1. Position the vehicle on a

level surface.

Maximum

Minimum

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.

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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. Check more often if brakes are used heavily under normal

operation.

1. Always keep brake fluid at an adequate

level. See page 76.

2. Check the brake systems regularly for

fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace the pads when

the friction material is worn to 1 mm.

1 mm

5. Check the security and surface condition

of the disc.

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MAINTENANCE

Toe Alignment

Do not attempt to adjust tie rod alignment. All tie rod adjustments should be

performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle.

The recommended toe alignment is 3-6 mm toe out.

1. Position the vehicle on a

level surface.

2. Place the handlebars in a

straight-ahead position.

Stand

String

3. Tie a length of string

between two stands as

shown in the illustration.

Position the stands so

that the string is flush

with the side of the rear

tire. If available, you may

use a long straight-edge

instead of string.

4. Measure the distance

from the string to the rim

at the front (1) and rear

(2) of the front rim. The

rear measurement should

be 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.

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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.

Improper adjustment of the handlebars or incorrect torquing of the adjuster

block tightening bolts can cause limited steering or loosening of the handlebars,

resulting in loss of control. Follow the adjustment procedures exactly, or see

your Polaris dealer for service.

1. Remove the upper headlight

pod.

2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the

desired height.

Tip: Be sure the handlebars do not con-

tact the gas tank or any other part

of the machine when turned fully to

the left or right.

4. Torque the front two bolts to

14-17 N-m, then torque the rear

two bolts. A gap of up to 3 mm

will remain at the rear bolts.

14-17 N-m

Rear Spring Adjustment

The rear shock absorber spring

is adjusted by rotating the

adjuster either clockwise or

counter-clockwise to increase

or decrease spring tension.

Adjuster

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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.

Footwell Removal

Rivets

1. Remove the four screws on

the bottom of the footwell.

2. Use a flat screwdriver or

sidecutters to remove the

plastic rivets securing the

footwell to the fenders.

3. Remove the footwell.

Screws

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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. Loosen the adjuster lock nut.

Lock Nut

Adjuster

4. Rotate the boot to turn the

adjuster until 1.6-3.2 mm of

freeplay is achieved at the

thumb lever. Move the throt-

tle lever back and forth while

adjusting.

1.6-3.2 mm

5. Tighten the lock nut.

6. Squeeze the end of the

rubber boot and slide it

over the cable adjuster to

its original position.

WARNING! Engine RPM should not increase when steering is turned full left or

right. Readjust cable freeplay if this occurs.

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MAINTENANCE

Tires

WARNING

Operating your vehicle with worn tires, improperly inflated tires, non-standard

tires or improperly installed tires will affect vehicle handling and could cause an

accident.

• Maintain proper tire pressure as described on the label on your vehicle and in

the specifications section of the owner's manual.

• Use only original equipment size and type when replacing tires.

• Make sure the wheels are installed properly.

• Replace tires when the tread depth measures 3 mm or less.

Refer to the specifications section beginning on page 114 for recom-

mended tire type, size and pressure.

Tire Tread Depth

Always replace tires

when tread depth is

worn to 3 mm or less.

3 mm

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.

Nut Type

Nut Torque

Lug Nut

122 Nm

2-Piece Flange Nut

37 Nm

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MAINTENANCE

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.

5. Remove the wheel nuts.

6. Remove the wheel.

7. Place the wheel on the hub.

8. Install the wheel nuts finger

tight.

9. Lower the vehicle to the

ground.

10. Torque the wheel nuts to

specification. See torque

chart on page 84.

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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. Remove the seat.

4. Release the air box

cover clips.

5. Remove the air

box cover.

6. Loosen the hose

clamp.

Pre-Filter

Main Filter

7. Remove the filter.

8. Remove the pre-filter

from the filter.

9. Wash the pre-filter in soapy water. Rinse and air dry.

10. Replace the filter if needed.

11. Reverse the steps to reinstall all components.

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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 82.

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 arrow to

check for clogging. Replace a

Breather

damaged or clogged filter.

Filter

4. Check the hoses for cracks, deterioration, abrasion, or leaks.

Replace as needed.

5. Reinstall the filter and hose clamps.

Tip: The filter is effective with the arrow pointing in either direction.

Operation of your vehicle without a breather filter can cause engine damage.

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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. Include rider

weight on the seat when measuring.

7.6 m

5 cm

4. Start the engine.Turn the headlight switch to high beam.

5. Observe the headlight aim on the wall. The most intense part of the

headlight beam should be 5 cm below the mark on the wall.

6. Tighten or loosen the lower headlight screws to adjust the beam

upward or downward or to the left or right.

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MAINTENANCE

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.

Oil from your skin leaves a residue,

causing a hot spot that will shorten

the life of the lamp. Hold the plastic

part of the lamp.

1. Place the transmission in PARK.

Position Light

2. Open the front rack cover.

3. Remove the plug at the back of the

headlight.

Headlamp

4. Pull the harness plug to disconnect

it from the back of the headlight.

5. Position light: Rotate the socket to

remove it. Go to step 6.

Collar

Headlamp: Reach under the

bumper and remove the rubber

cover from the back of the

headlight. Turn the collar counter-

clockwise and carefully remove

the collar and socket.

6. Remove the lamp. Apply dielectric

grease to the socket and install a

new lamp.

Socket

7. Reverse all steps to reassemble the

headlight.

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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. Reinstall all components in reverse order.

Front Turn Signal Lamp Replacement

1. Place the transmission in

PARK.

2. Remove the lens attachment

screw.

3. Rotate the lamp to remove it.

4. Install the new lamp.

5. Reinstall the lens.

Screw

Lamp

Rear Turn Signal Lamp Replacement

1. Place the transmission in PARK.

2. Rotate the turn signal 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. Reinstall all components in reverse order.

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MAINTENANCE

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.

2. Remove the suspect fuse from

the fuse panel. If the fuse is

blown, install a new fuse with

the same amperage.

3. Secure the access door.

4. Secure the box cover.

Fuses

Fuse Panel

5or6 15 20 20

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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

Torque Specification

New Spark Plug

12-15 N-m

23-27 N-m

Previously Installed Spark Plug

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark

plug firing end condition after the engine has been warmed up and the

vehicle has been driven at higher speeds. Immediately check the spark

plug for correct color. See page 93.

Normal Spark Plug

The normal insulator tip is tan or brown. There will be few combustion

deposits. The electrodes are not burned or eroded. This indicates the

proper type and heat range for the engine and the service.

The tip should not be white. A white insulator tip indicates overheating,

caused by use of an improper spark plug or incorrect carburetor adjust-

ments.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil, use

of non-recommended oil, improper use of the choke, or incorrect carbu-

retor adjustments.

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MAINTENANCE

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.

Replace worn or fouled

plugs. Verify that the gap is

at specification before

installation.

5. Reinstall the spark plug.

Torque to specification. See

page 92.

6. Reinstall the spark plug cap.

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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. Take the vehicle to your dealer before

starting the engine.

1. Move the vehicle out of the

water.

2. Turn the fuel valve off.

3. Drain any water found in the air box.

4. Remove the spark plug.

5. Loosen the carburetor drain screw and drain

the carburetor.

6. Turn the engine over several times using the

electric start.

Drain Screw

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MAINTENANCE

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.

11. Have the vehicle serviced by

your dealer promptly, whether

you succeed in starting it or not.

12. If water has been ingested into the PVT, follow the procedure on

page 99 for drying out the PVT.

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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. Never go under the vehicle while it's

inclined.

Remove any combustible materials from the area. Wear eye protection and

leather work gloves. Do not stand behind or in front of the vehicle while purging.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the arrestor

clean-out plug from the

bottom of the muffler.

4. Start the engine.

5. Quickly squeeze and

release the throttle lever

several times to purge car-

bon from the system.

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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. Block the

wheels.

9. Place the transmission in

PARK. Repeat steps 5 to 7 until

no more particles are expelled.

30 cm

10. Stop the engine. Allow the arrestor to cool.

11. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

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MAINTENANCE

PVT System

Do not modify any component of the PVT system. Doing so may reduce its

strength so that a failure may occur at a high speed. The PVT system has been

precision balanced. Any modification will cause the system to be out of balance,

creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on

clutch components. Extensive engineering and testing has been conducted to

ensure the safety of this product. However, as the owner, you have the following

responsibilities to make sure this system remains safe:

• 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.

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MAINTENANCE

PVT System

When To Use Low Range and High Range

Condition

Range to Use

Operating at speeds less than 11 km/h

Towing heavy loads

Low

High

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. 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.

Reinstall the drain

plug.

4. Start the engine.

5. Apply varying throttle for 10-15 seconds to expel the moisture and

air-dry the belt and clutches. Do not hold the throttle wide open for

more than 10 seconds.

6. Allow the engine RPM to settle to idle speed, then shift the trans-

mission to the lowest available range.

7. Test for belt slippage. If the belt slips, repeat the process.

8. Take the vehicle to your dealer for service as soon as possible.

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MAINTENANCE

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.

Recoil Housing

1. Place the transmission in PARK.

2. Stop the engine.

3. Remove the drain screw on the

bottom of the recoil housing.

4. Allow the housing to drain com-

pletely.

5. Reinstall the drain screw.

Tip: Do not open the crankcase drain

unless the engine has ingested water.

On 4-cycle engines, some engine oil

will be lost if the crankcase drain is

opened.

100

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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. It contains sulfuric acid. Serious burns can

result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes

when working near batteries. KEEP OUT OF REACH OF CHILDREN.

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. If

cleaning is necessary, remove corrosion with a stiff wire brush. Wash

with a solution of one tablespoon baking soda and one cup water. Rinse

well with tap water and dry off with clean shop towels. Coat the termi-

nals with dielectric grease or petroleum jelly. Be careful not to allow

cleaning solution or tap water into a conventional battery.

101

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MAINTENANCE

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. Disconnect the red (positive) battery cable last.

8. Lift the battery out of the vehicle. Be careful not to tip a conven-

tional battery sideways, which could spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the

vehicle.

102

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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). The vent tube must be free of

obstructions and securely installed. Route the tube away from the

frame and vehicle body to prevent contact with electrolyte.

Battery gases could accumulate in an improperly installed vent tube and cause

an explosion, resulting in serious injury or death. Always ensure that the vent

tube is free of obstructions and is securely installed as recommended.

4. On conventional batteries, coat the terminals with dielectric grease

or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Secure the battery hold-down strap.

8. Reinstall the battery cover (if equipped).

9. Verify that cables are properly routed. Cables should be safely

tucked away at the front and rear of the battery.

10. Reinstall the seat.

103

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MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more,

remove the battery from the vehicle, ensure that it's fully charged, and

store it out of the sun in a cool, dry place. 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. 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. See page 116 for the part numbers of

Polaris products.

Battery Fluid (Conventional Battery)

Check the battery fluid level

often. Maintain the fluid level

between the upper and lower

level marks.

Lower

Mark

Upper

Mark

Add only distilled water. Tap

water contains minerals that are

harmful to a battery.

104

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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 102.

2. Charge the battery with a charging output no larger than 1/10 of the

battery’s amp/hr rating. Charge as needed to raise the specific grav-

ity to 1.270 or greater.

3. Reinstall the battery. See page 103. Make sure the positive terminal

is toward the front of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installa-

tion of a sealed battery. Read all instructions before proceeding with the

installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed

and fully charged at the factory. Never pry the sealing strip off or add

any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to

keep it fully charged. Since the battery is sealed and the sealing strip

cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

105

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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.

3. When using an automatic charger, refer to the charger manufac-

turer's instructions for recharging. When using a constant current

charger, use the following guidelines for recharging.

An overheated battery may explode, causing severe injury or death. Always

watch charging times carefully. Stop charging if the battery becomes very warm

to the touch. Allow it to cool before resuming charging.

Always verify battery condition before and 1-2 hours after the end of

charging.

Charge Time

State of

Charge

(Using constant current

Voltage

Action

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

None, check at 3

mos. from date of

manufacture

None required

75%-100%

12.5-12.8 volts

May need slight

charge, if no

3-6 hours

charge given,

check in 3 months

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

106

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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.

Certain products, including insect repellents and chemicals, will damage

plastic surfaces. Do not allow these types of products to contact the

vehicle.

1. Use a professional-type washing cloth, cleaning the upper body first

and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

107

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended),

exercise extreme caution. The water may damage components and could

remove paint and labels. Avoid directing the water stream at the follow-

ing items:

• Wheel bearings

• Radiator

• Transmission seals

• Brakes

• Cab and body panels

• Electrical components

• Switches and controls

• Labels and decals

If an informational or graphic label becomes illegible or comes off, con-

tact your Polaris dealer to purchase a replacement. Replacement safety

labels are provided by Polaris at no charge.

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.

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.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

108

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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.

Chrome wheels exposed to road salt (or salt in the air in coastal areas)

are more susceptible to corrosion if not properly cleaned. Clean chrome

wheels more often if they're exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use

abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive

grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol-

ished chrome wheel. Choose a product suitable for chrome finishes.

Read and follow the product labels and instructions.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT

grade) to remove it. Gently rub the affected areas with the steel wool

until the corrosion has been removed. Clean and polish the wheel as out-

lined above.

109

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MAINTENANCE

Cleaning and Storage

Storage Tips

Starting the engine during the storage period will disturb the protective film

created by fogging and damage could occur. Never start the engine during the

storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See

page 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.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to

disperse through the fuel tank and carburetor.

4. Turn the fuel valve off.

5. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 65.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter.

2. Clean the air box.

3. Clean or replace the breather filter.

4. Drain the sediment tube.

Recoil Housing (if equipped)

1. Drain the recoil housing. See page 100.

110

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MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Change fluids as recommended in the Periodic

Maintenance Chart beginning on page 57.

• Demand drive unit (front gearcase)

• Transmission

• Rear gearcase (if equipped)

• Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

• Coolant (test strength/fill)

Fog the Engine

1. Treat the fuel system with Polaris Carbon Clean. See page 110.

2. Remove the spark plug. Pour 30-45 ml of engine oil into the plug

holes.

3. Reinstall the spark plugs. Torque to specification.

4. Apply dielectric grease to the inside of each spark plug cap. Rein-

stall the caps.

5. Turn the engine over several times (using the recoil starter, if

equipped). 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.

7. To eliminate any fuel remaining in the carburetor, run the engine

until it stops.

111

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MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended

in the Periodic Maintenance Chart beginning on page 57.

Battery Storage

See pages 104-105 for storage and charging procedures.

Storage Area/Covers

1. Set the tire pressure and safely support the vehicle with the tires

slightly off the ground.

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.

Accessories

Auxiliary power outlets provide 12-volt power for operating accesso-

ries. Accessory outlets are available for all models. Polaris also has a

wide range of additional accessories available for your vehicle. Always

install accessories that are approved for use on this vehicle. Please see

your Polaris dealer.

112

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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 Polaris vehicle to the transporting unit

securely with suitable straps or rope. Do not attach tie straps to the

front A-arm bolt pockets.

Towing a Disabled Vehicle

If towing the vehicle is necessary, shift the transmission into neutral for

better mobility and to prevent damage to the belt.

Always attach the tow rope to the frame of the Polaris vehicle.

113

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SPECIFICATIONS

Sportsman 500 HO International

Gross Vehicle Weight

Maximum Weight Capacity

Dry Weight

1200 lbs. (544 kg)

485 lbs. (220 kg) (operator, cargo, accessories)

696 lbs. (316 kg)

Fuel Capacity

4.25 gal. (16 l)

Engine Oil Capacity

Coolant Capacity

2 qts. (1.9 l)

2.7 qts. (2.5 l)

Demand Drive Fluid Capacity

Transmission Oil Capacity

6 oz. (175 ml)

32 oz. (948 ml)

Front Rack/Storage Box Capacity 90 lbs. (41 kg)

Rear Rack/Storage Box Capacity 180 lbs. (81.6 kg)

Receiver Hitch Tongue Capacity 120 lbs. (55 kg) (Rear rack capacity and tongue

(Off-road use only)

weight not to exceed 180 lbs./81.6 kg)

Hitch Towing Rating

1225 lbs. (555.7 kg)

Unbraked Trailer Towing

Capacity*

1786 lbs. (810 kg)

Overall Length

Overall Width

Overall Height

Wheelbase

Ground Clearance

Minimum Turning Radius

Engine

83 in. (211 cm)

48 in. (122 cm)

50.5 in. (128.3 cm)

11.25 in. (28.5 cm)

65 in. (165 cm) unloaded

EH500PLE

Displacement

Bore x Stroke

Alternator Output

Compression Ratio

Carburetor

498 cc

92 x 75

260 w

10.2:1

40mm Mikuni

Pilot Jet

Main Jet

155

Needle Jet

X-6M

Jet Needle

6MGHI 194

Pilot Screw

By flow (taper 12.5°) (Brass Plug)

Digital CDI

30° +/- 2° @ 5000 RPM

NGK BKR6E / .035 in. (0.9 mm)

Dry Sump

Ignition System

Ignition Timing

Spark Plug / Gap

Lubrication System

* Based on EU Directive 76/432/EC

114

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SPECIFICATIONS

Sportsman 500 HO International

Driving System Type

Front Suspension

Rear Suspension

Shift Type

Automatic PVT (Polaris Variable Transmission)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 9.5" (24 cm) travel

Side Lever (H/L/N/R/P)

23.91:1

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, Forward

Drive Ratio, Front

Tires/Pressure, Front

Tires/Pressure, Rear

Brake, Hand

16.30:1

10.49:1

3.82:1

25x8-12 / 5 psi (34.5 kPa)

25x12.5-12 / 5 psi (34.5 kPa)

All-wheel hydraulic disc

Brake, Foot

Brake, Parking

Transmission park lock and hydraulic lock, all

wheel

Headlight

2 Hi/Lo beam on bumper (37.5 watt)

Taillights

8.26 watts

26.9 watts

LCD

Brake Light

Instrument Cluster

Jetting Chart

AMBIENT TEMPERATURE

ALTITUDE

Meters (Feet)

Below 40° F

+40°F and above

(+5°C and above)

(Below 5° C)

0-1800 (0-6000)

160

155

1800-3700

(6000-12000)

152.5

147.5

Clutching

Altitude

Shift

Weight

Drive Clutch

Driven

Clutch

Spring

Helix and

Spring

Setting

Spring

Meters

(Feet)

0-1800

(0-6000)

10 WH

Blue/Green

Black

PN 7041782

41-37°

PN 5132344

2+2

PN 5630710 PN 7041157

1800-3700

10 RH

Blue/Green

Black

PN 7041782

41-37°

PN 5132344

2+2

(6000-12000) PN 5630709 PN 7041157

115

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POLARIS PRODUCTS

Part Number

Description

Engine Lubricant

2870791

2871281

2871844

Fogging Oil (12 oz. Aerosol)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (.95 l)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (3.8 l)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lubricant (.95 l)

Premium AGL Synthetic Gearcase Lube (3.8 l)

Demand Drive Plus Fluid (qt./.95 l)

Demand Drive Plus Fluid (gal./3.8 l)

Pump for 3.8 liter jug

2873602

2873603

2877922

2877923

2870465

2871654

2872277

Premium Demand Drive Hub Fluid (237 ml)

Premium Demand Drive Hub Fluid (9.5 l)

Coolant

2871323

2871534

60/40 Coolant (3.8 l)

60/40 Coolant (.95 l)

Grease / Specialized Lubricants

Grease Gun Kit, Premium All Season

Premium All Season Grease (89 ml cartridge)

Premium All Season Grease (414 ml cartridge)

Starter Drive Grease

2871312

2871322

2871423

2871460

2871515

2871551

2871329

2872073

2872348

Premium U-Joint Lube (89 ml)

Premium U-Joint Lube (414 ml)

Dielectric Grease (Nyogel^TM

)

Chain Lube, Aerosol (185 ml)

Chain Lube, Aerosol (473 ml)

Additives / Miscellaneous

Carbon Clean Plus

2871326

2870652

2872189

2872893

2871956

2871076

Fuel Stabilizer

DOT4 Brake Fluid

Engine Degreaser

Loctite^TM565 Thread Sealant

Polaris Battery Tender^TMCharger

116

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TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause

Solution

Driving onto a pickup or Use low range.

tall trailer in high range

Starting out going up a

steep incline

Use low range or turn around using the K-turn (see page

26).

Driving at low RPM or

speed (5-11 km/h)

Drive at a higher speed or use low range more frequently.

Insufficient warm-up at

low ambient tempera-

tures

Warm the engine at least 5 minutes. With the transmission

in neutral, advance the throttle to about 1/8 throttle in

short bursts, 5 to 7 times. The belt will become more flex-

ible and prevent belt burning.

Slow/easy clutch engage- Use the throttle quickly and effectively.

ment

Towing/pushing at low

RPM/low ground speed

Use low range only.

Utility use/plowing

Use low range only.

Stuck in mud or snow

Shift the transmission to low range. Carefully use fast,

aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Climbing over large

objects from a stopped

position

Belt slippage from water Dry out the PVT. See page 99. Inspect clutch seals for

or snow ingestion into the damage if repeated leaking occurs.

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

warm up belt

Always warm up the belt by operating below 48 km/h for

1.6 km. Operate 8 km or more when temperature is below

freezing.

Wrong or missing belt

Improper break-in

Install the recommended belt.

Always break in a new belt and/or clutch. See page 52.

117

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TROUBLESHOOTING

Engine Does Not Rotate

Possible Cause

Solution

Reset the breaker

Tripped circuit breaker

Low battery voltage

Recharge the battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Rotates, Fails to Start

Possible Cause

Solution

Out of fuel

Refuel

Clogged fuel valve or filter

Water is present in fuel

Old or non-recommended fuel

Fuel valve is turned off

Fouled or defective spark plug(s)

No spark to spark plug

Water or fuel in crankcase

Low battery voltage

Replace the filter

Drain the fuel system and refuel

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

Mechanical failure

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Loose ignition connections

Water present in fuel

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Check all connections and tighten

Replace with fresh recommended fuel

See your dealer

Incorrectly installed spark plug wires

Incorrect ignition timing

See your dealer

Mechanical failure

See your dealer

118

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TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

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)

Inspect, clean and/or replace spark

plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

See your dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Recharge battery to 12.8 VDC

Inspect and replace

Low battery voltage

Kinked or plugged fuel tank vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your dealer

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Kinked or plugged fuel vent line

Incorrect fuel

Inspect and replace (if equipped)

Replace with recommended fuel

See your Polaris dealer

Incorrect jetting

Possible Rich Fuel Cause

Solution

Fuel is very high octane

Overuse of choke

Replace with lower octane fuel

Inspect, clean and/or replace spark plugs

Stopping/starting without adequate

warm-up

Allow engine to warm up before operat-

ing and/or stopping

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Clogged air filter

Incorrect jetting

119

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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

Overuse of choke

Inspect and replace (if equipped)

Inspect, clean and/or replace spark plugs

Replace with fresh recommended fuel

Water is present in fuel

Old or non-recommended fuel

Fouled or defective spark plug(s)

Inspect, clean and/or replace spark

plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

See your dealer

Set gap to specs or replace plug

Check all connections and tighten

Recharge the battery to 12.8 VDC

Replace with fresh recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your dealer

Clean radiator screen and core, clean

engine exterior, see your dealer

Engine Overheating

Possible Cause

Solution

Debris lodged in screen

Remove and clean the screen. Pull on the

top portion of the screen, then remove the

lower portion.

Plugged Radiator

Use a garden hose to flush any debris

from the radiator fins. NOTE: High

pressure washers can deform the radiator

fins and reduce cooling efficiency.

120

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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

TEST / EVALUATION METHODS

98/37/EC as amended (Machinery Directive)

EN 1050 hazard analysis

CD 77/311/EEC driver-perceived noise level

2004/108/EC as amended (EMC Directive)

CISPR 12:2001

CAN/CSA-C108.4-M92

EN 55012:2002

EN 61000-6-2:2001

PRODUCT IDENTIFICATION

VEHICLE SERIES

TRADE NAME

MODEL

YEARS

SOUND

PRESSURE

dB (A)

___KA05__

___KA09__

___FA09__

___VA17__

___PB20__

___BA32__

___CA32__

___BA50__

___GJ45__

___GJ52__, ___GP52__

___LH27__

___LH46__

___MN50__

OUTLAW 50

OUTLAW 90

SPORTSMAN 90

RZR 170

PHOENIX 200

TRAIL BLAZER 330

TRAIL BOSS 330

SCRAMBLER 500

OUTLAW 450

2008, 2009, 2010

2009, 2010

76.8

81.3

76.8

79.6

80.7

81.1

80.2

80.4

80.8

77.2

83.6

77.2

80.1

80.4

76.5

85.8

2008, 2009, 2010

2009, 2010

OUTLAW 525

SPORTSMAN 300

SPORTSMAN 400

SPORTSMAN 500 EFI

SPORTSMAN 550 EFI

___ZN55__ ___ZX55__

___TN55__, ___DN55__ SPORTSMAN X2/TOURING 550 2010

___MN76__ SPORTSMAN 800 2008, 2009, 2010

___TN85__, ___DN85__ SPORTSMAN X2/TOURING 850 2010

___CL76__

___ZN85__, ___ZX85__

SPORTSMAN 800 6X6

SPORTSMAN 850 EFI

2009, 2010

2010

___RH50__, ___HH50__ RANGER 500 EFI 4X4

___HH76__

___WH76__

___HR__

___HY__

___VH76__

RANGER 800 EFI 4X4

RANGER 800 EFI CREW

RANGER 800 6X6

RANGER HD 800 4X4

RANGER RZR

2010

2008, 2009, 2010

Authorized Signatory:

__________________________________

Alexander A. Kennedy, Product Compliance

Polaris Industries Inc., Engineering Operations

301 5th Avenue SW, Roseau, MN 56751

121

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WARRANTY

LIMITED WARRANTY

Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR

LIMITED WARRANTY on all components of the Polaris vehicle against defects in

material or workmanship. This warranty covers the parts and labor charges for repair or

replacement of defective parts which are covered by this warranty. This warranty begins

on the date of purchase. This warranty is transferable to another consumer during the

warranty period through a Polaris dealer.

REGISTRATION

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

SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO

HAVE VALID WARRANTY ON THE VEHICLE. No verification of registration will

be sent to the purchaser as the copy of the Warranty Registration Form will be the war-

ranty entitlement. If you have not signed the original registration and received the "cus-

tomer copy", please contact your dealer immediately. NO WARRANTY COVERAGE

WILL BE ALLOWED UNLESS YOUR POLARIS VEHICLE IS REGISTERED

WITH POLARIS.

Initial dealer preparation and set-up of your vehicle is very important in ensuring trou-

ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will

void your warranty coverage.

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

has been altered structurally, modified, neglected, improperly maintained, used for rac-

ing, or used for purposes other than for which it was manufactured, or for any damages

which occur during trailer transit or as a result of unauthorized service or the use of

unauthorized parts. In addition, this warranty does not cover physical damage to paint or

finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in

parts, components or the vehicle due to fire, explosions or any other cause beyond

Polaris' control.

122

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WARRANTY

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

•

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Suspension components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Drive belts

Hydraulic components

Circuit breakers/Fuses

Electronic components

Light bulbs/Sealed beam lamps

Warranty applies to the product only and does not allow for coverage of personal loss.

Some items are considered "consumable," meaning they are considered part of normal

maintenance or part of completing an effective repair. The following items are excluded

from warranty coverage in the event of a warranty claim:

•

Spark Plugs

Filters

Fuel

Sealants

Hotel fees

Towing charges

Mileage

Rentals/Loss of product use

•

Lubricants such as oil, grease, etc.

Batteries (unless defective)

Cosmetic damage/repair

Coolants

Meals

Shipping/ handling fees

Product pick-up/delivery

Loss of vacation/personal time

This warranty also excludes failures resulting from improper lubrication; improper

engine timing; improper fuel; surface imperfections caused by external stress, heat, cold

or contamination; operator error or abuse; improper component alignment, tension,

adjustment or altitude compensation; failure due to snow, water, dirt or other foreign

substance ingestion/contamination; improper maintenance; modified components; use

of aftermarket components resulting in failure; unauthorized repairs; repairs made after

the warranty period expires or by an unauthorized repair center; use of the product in

competition or for commercial purposes. Warranty will not apply to any product which

has been damaged by abuse, accident, fire or any other casualty not determined a defect

of materials or workmanship.

123

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WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the vehicle. The exclusive remedy for breach of this warranty

shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or

components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE

THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR

INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP-

TION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR

ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.

Some states do not permit the exclusion or limitation of incidental or consequential

damages or implied warranties, so the above limitations or exclusions may not apply to

you if inconsistent with controlling state law.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO

YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-

tations on how long an implied warranty lasts, so the above limitation may not apply to

you if inconsistent with controlling state law.

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. (THE COST OF TRANSPORTATION

TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that

you use your original selling dealer; however, you may use any Polaris Servicing Dealer

to perform warranty service.

Please work with your dealer to resolve any warranty issues. Should your dealer require

any additional assistance they will contact the appropriate personnel at Polaris.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty

terms will remain in effect.

124

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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

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

125

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MAINTENANCE LOG

DATE KILOMETERS

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

126

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MAINTENANCE LOG

DATE KILOMETERS

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

127

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INDEX

Accessories . . . . . . . . . . . . . . . . . . 112

Age Restrictions. . . . . . . . . . . . . . . . . 5

Air Filter . . . . . . . . . . . . . . . . . . . . . 86

All Wheel Drive Switch. . . . . . . . . . 36

All Wheel Drive System . . . . . . . . . 44

Demand Drive Fluid . . . . . . . . . . 71-72

Drive Belt Wear/Burn . . . . . . . . . . . 117

Drivetrain Break-In . . . . . . . . . . . . . . 52

Driving Downhill. . . . . . . . . . . . . . . . 25

Driving in Reverse. . . . . . . . . . . . . . . 31

Driving on a Sidehill . . . . . . . . . . . . . 24

Driving on Slippery Surfaces . . . . . . 20

Driving Over Obstacles . . . . . . . . . . . 21

Driving Procedures . . . . . . . . . . . . . . 18

Driving Safely . . . . . . . . . . . . . . . 18-33

Driving Through Water . . . . . . . . 28-29

Driving Uphill . . . . . . . . . . . . . . . 22-23

Battery . . . . . . . . . . . . . . . . . . 101-106

Charging (Conventional) . . . . 105

Charging (Sealed) . . . . . . 105-106

Fluid (Conventional) . . . . . . . 104

Installation . . . . . . . . . . . . . . . 103

Removal. . . . . . . . . . . . . . . . . 102

Storage. . . . . . . . . . . . . . . . . . 104

Boots . . . . . . . . . . . . . . . . . . . . . . . . 17

Brake Fluid . . . . . . . . . . . . . . . . . 76-78

Brake Inspections. . . . . . . . . . . . . . . 79

Brake, Foot . . . . . . . . . . . . . . . . . . . 38

Brake, Hand. . . . . . . . . . . . . . . . . . . 38

Brake, Parking . . . . . . . . . . . . . . . . . 39

Brakes . . . . . . . . . . . . . . . . . . . . . . . 79

Break-In Period . . . . . . . . . . . . . . . . 52

Breather Filter . . . . . . . . . . . . . . . . . 87

Breather Hose . . . . . . . . . . . . . . . . . 87

Electromagnetic Interference. . . . . . . 56

Electronic Throttle Control . . . . . . . . 37

Engine Break-In. . . . . . . . . . . . . . . . . 52

Engine Fogging . . . . . . . . . . . . . . . . 111

Engine Idle RPM Adjustment . . . . . . 73

Engine Oil . . . . . . . . . . . . . . . . . . 63-68

Equipment Modifications . . . . . . . . . . 5

Exhaust Emission Control System . . 56

Eye Protection . . . . . . . . . . . . . . . . . . 17

Fluid, Brake . . . . . . . . . . . . . . . . . 76-78

Fluid, Demand Drive. . . . . . . . . . 71-72

Foot Brake . . . . . . . . . . . . . . . . . . . . . 38

Footwell Removal . . . . . . . . . . . . . . . 82

Front Gearcase. . . . . . . . . . . . . . . 71-72

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 41

Fuel Safety. . . . . . . . . . . . . . . . . . . . . 51

Fuel Tank Cap . . . . . . . . . . . . . . . . . . 41

Fuel Valve . . . . . . . . . . . . . . . . . . . . . 41

Fuse Replacement . . . . . . . . . . . . . . . 91

Carburetor . . . . . . . . . . . . . . . . . . . . 73

Carburetor Adjustment . . . . . . . . . . 73

Cargo . . . . . . . . . . . . . . . . . . . . . . 32-33

Choke. . . . . . . . . . . . . . . . . . . . . . . . 41

Chrome Wheel Care . . . . . . . . . . . 109

Cleaning and Storage. . . . . . . . 107-112

Clothing . . . . . . . . . . . . . . . . . . . . . . 17

Clutching . . . . . . . . . . . . . . . . . . . . 115

Cold Weather Operation . . . . . . . . . 55

Coolant Bottle . . . . . . . . . . . . . . . . . 74

Coolant, Radiator. . . . . . . . . . . . . . . 75

Cooling System . . . . . . . . . . . . . . 74-75

Corrosion Removal, Chrome. . . . . 109

Gear Selector . . . . . . . . . . . . . . . . . . . 42

Gloves . . . . . . . . . . . . . . . . . . . . . . . . 17

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INDEX

Handlebar Adjustment . . . . . . . . . . . 81

Hauling Cargo. . . . . . . . . . . . . . . 32-33

Hazard Warning Switch . . . . . . . . . . 36

Headlight Beam Adjustment. . . . . . . 88

Headlight Lamp . . . . . . . . . . . . . . . . 89

Helmet. . . . . . . . . . . . . . . . . . . . . . . . 16

High Range Use . . . . . . . . . . . . . . . . 99

Horn Switch . . . . . . . . . . . . . . . . . . . 36

Oil

Engine. . . . . . . . . . . . . . . . . 63-68

Transmission. . . . . . . . . . . . 69-70

Oil Change

Engine. . . . . . . . . . . . . . . . . 65-68

Transmission. . . . . . . . . . . . . . . 70

Oil Level

Engine. . . . . . . . . . . . . . . . . . . . 64

Transmission. . . . . . . . . . . . . . . 69

Oil Pump Priming. . . . . . . . . . . . . . . 68

Oil Recommendations

Engine. . . . . . . . . . . . . . . . . . . . 63

Transmission. . . . . . . . . . . . . . . 69

Operator Safety. . . . . . . . . . . . . . . 7-13

Override Switch . . . . . . . . . . . . . . . . 34

Idle RPM Adjustment . . . . . . . . . . . . 73

Immersion . . . . . . . . . . . . . . . . . . 94-95

Instrument Cluster. . . . . . . . . . . . 45-50

Jetting Chart . . . . . . . . . . . . . . . . . . 115

Parking Brake . . . . . . . . . . . . . . . . . . 39

Parking on an Incline . . . . . . . . . . . . 30

Periodic Maintenance Chart . . . . 57-61

Polaris Product List. . . . . . . . . . . . . 116

Polishing the Vehicle . . . . . . . . . . . 108

Position Light Lamp . . . . . . . . . . . . . 89

Pre-Ride Checklist . . . . . . . . . . . . . . 53

PVT Break-In . . . . . . . . . . . . . . . . . . 52

PVT Drying . . . . . . . . . . . . . . . . . . . 56

PVT System . . . . . . . . . . . . . . . . 98-99

Key Switch . . . . . . . . . . . . . . . . . . . . 35

K-Turn . . . . . . . . . . . . . . . . . . . . 26-27

Light Switch . . . . . . . . . . . . . . . . . . . 35

Lights . . . . . . . . . . . . . . . . . . . . . 88-90

Front Turn Signal . . . . . . . . . . . 90

Headlight Beam Adjustment. . . 88

Headlight Lamp . . . . . . . . . . . . 89

Position Light Lamp . . . . . . . . . 89

Rear Turn Signal. . . . . . . . . . . . 90

Taillight. . . . . . . . . . . . . . . . . . . 90

Low Range Use. . . . . . . . . . . . . . . . . 99

Lubrication Guide. . . . . . . . . . . . . . . 62

Recoil Housing . . . . . . . . . . . . . . . . 100

Recoil Starter . . . . . . . . . . . . . . . . . . 43

Reverse Operation . . . . . . . . . . . . . . 31

Reverse Override Switch . . . . . . . . . 34

Rider Information Center . . . . . . 46-50

Riding Gear. . . . . . . . . . . . . . . . . 16-17

Maintenance Chart . . . . . . . . . . . 57-61

Mirrors . . . . . . . . . . . . . . . . . . . . . . . 37

Mode Switch. . . . . . . . . . . . . . . . . . . 34

Modifications . . . . . . . . . . . . . . . . . . . 5

Safety Labels . . . . . . . . . . . . . . . 14-15

Age 16 Alert . . . . . . . . . . . . . . . 14

General Alert . . . . . . . . . . . . . . 14

Hill Operation Alert . . . . . . . . . 14

No Passenger Warning . . . . . . . 15

Rack Warning, Front and Rear . 15

Reverse Override Alert. . . . . . . 15

Tire Pressure/Load Alert. . . . . . 15

Noise Emission Control System . . . . 56

129

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INDEX

Safety Training . . . . . . . . . . . . . . . . . 5

Service Interval Programming. . . . . 50

Severe Use . . . . . . . . . . . . . . . . . . . . 57

Side Panel Removal. . . . . . . . . . . . . 82

Sidehilling . . . . . . . . . . . . . . . . . . . . 24

Signal Words . . . . . . . . . . . . . . . . . . . 4

Spark Arrestor . . . . . . . . . . . . . . . 96-97

Spark Arrestor Requirements . . . . . 56

Spark Plugs . . . . . . . . . . . . . . . . . 92-93

Specifications. . . . . . . . . . . . . . 114-115

Spring Adjustment, Rear . . . . . . . . . 81

Starting the Engine . . . . . . . . . . . 54-55

Steering Assembly. . . . . . . . . . . . . . 81

Steering Lock. . . . . . . . . . . . . . . . . . 40

Stop Switch . . . . . . . . . . . . . . . . . . . 35

Storage. . . . . . . . . . . . . . . . . . . 107-112

Switches . . . . . . . . . . . . . . . . . . . 34-36

AWD Switch . . . . . . . . . . . . . . 36

Engine Stop Switch . . . . . . . . . 35

Hazard Warning. . . . . . . . . . . . 36

Horn. . . . . . . . . . . . . . . . . . . . . 36

Light Switch . . . . . . . . . . . . . . 35

Main Key Switch. . . . . . . . . . . 35

Mode/Reverse Override Switch 34

Turn Signal . . . . . . . . . . . . . . . 36

Taillight . . . . . . . . . . . . . . . . . . . . . . . 90

Throttle Cable Freeplay. . . . . . . . . . . 83

Throttle Lever . . . . . . . . . . . . . . . . . . 37

Tire Tread Depth . . . . . . . . . . . . . . . . 84

Tires . . . . . . . . . . . . . . . . . . . . . . 84-85

Front Wheel Hub Tightening. . . 84

Tread Depth. . . . . . . . . . . . . . . . 84

Wheel Installation . . . . . . . . . . . 85

Wheel Nut Torque . . . . . . . . . . . 84

Wheel Removal . . . . . . . . . . . . . 85

Toe Alignment. . . . . . . . . . . . . . . . . . 80

Towing a Disabled Vehicle . . . . . . . 113

Towing Loads . . . . . . . . . . . . . . . . . . 33

Training, Safety . . . . . . . . . . . . . . . . . . 5

Transmission Oil . . . . . . . . . . . . . 69-70

Transporting the Vehicle . . . . . . . . . 113

Turn Signal Lamp, Front . . . . . . . . . . 90

Turn Signal Lamp, Rear . . . . . . . . . . 90

Turn Signal Switch . . . . . . . . . . . . . . 36

Turning Around on a Hill . . . . . . 26-27

Turning the Vehicle. . . . . . . . . . . . . . 19

Vehicle Identification Numbers. . . . . . 6

Vehicle Immersion . . . . . . . . . . . 94-95

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle . . . . . . . . 107-108

Wheel Hub Tightening . . . . . . . . . . . 84

Wheel Installation . . . . . . . . . . . . . . . 85

Wheel Nut Torque Specifications . . . 84

Wheel Removal . . . . . . . . . . . . . . . . . 85

130

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