Pantone 426c Sportsman 500 Touring International 2010 Owner's Manual for Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
Pantone 426c PASSENGER UNDER 12 GB Before you operate or ride this vehicle, read the owner’s manual. D Lesen Sie die Bedienungsanleitung, bevor Sie dieses Fahrzeug bedienen oder fahren. E Antes de operar o conducir este vehículo, lea el Manual del propietario. F Lire le Manuel d’utilisation avant d’utiliser ou de conduire ce véhicule. I Prima di usare o guidare il veícolo, leggere il Manuale di istruzioni. FI Lue aina käyttöohjekirja ennen tämän ajoneuvon käyttöä tai ajamista.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide 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.
POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Emission Control Systems . . . . . . . . . . . . . . . 60 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 118 Polaris Products.
INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols 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.
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.
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.
SAFETY WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.
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 standards. 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.
Safe Riding Gear SAFETY Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever 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.
SAFETY Rider Safety 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.
Rider Safety 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. Always inspect your vehicle before each use to verify that it's in safe operating condition.
SAFETY Rider Safety Keep both hands on the handlebars. Keep both feet on the footrests. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator. Always travel slowly when operating on unfamiliar 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 43.
SAFETY Rider Safety Always follow the procedures outlined in this manual for driving on hills. See page 46. 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 15°. >15° Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 49. Always follow the procedures outlined in this manual for crossing the side of a hill. See page 48.
SAFETY Rider Safety Always follow the procedures outlined in this manual for operating over obstacles. See page 55. 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 54. Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 52. Always follow the procedures outlined in this manual for driving in reverse.
Rider Safety SAFETY Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify the vehicle through improper installation or use 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. Never operate the vehicle on a frozen body of water.
SAFETY Rider Safety 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 28. Handling Gasoline Gasoline is highly flammable and explosive under certain conditions.
SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal. The following pages repeat the information found on each decal.
SAFETY Safety Decals and Locations Reverse Override Alert Front Rack Warning + + Clutch Cover Alert + + Rear Rack Warning + Tire Pressure/ Load Alert Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 568 LBS. (258 kg) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES. Read Owner's Manual for more detailed loading information.
Safety Decals and Locations SAFETY Rack Warning, Front and Rear WARNING 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.
FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Engine Stop Switch Hazard Switch Headlight Switch 4X4 Switch Main Key Switch Choke Horn Switch Turn Signal Switch Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 32. To gain additional power while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse speed limit function.
Switches FEATURES AND CONTROLS 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.
FEATURES AND CONTROLS Switches 4X4 Switch Use the 4X4 switch to engage 4X4 or 2X4. See page 30. Hazard Warning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.
Switches FEATURES AND CONTROLS 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 Turn Signal Switch Horn Switch Press the horn switch to sound the horn.
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 the vehicle with sticking or improperly operating throttle controls.
Foot Brake FEATURES AND CONTROLS 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.
FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze the brake lever toward the handlebar. 3. Push the parking brake lock forward to engage the lock. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever. 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.
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 39, cranking the engine with the recoil Handle starter instead of the main key switch. Recoil 1. Grasp the recoil starter rope Starter handle tightly. 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.
FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. 1. Turn the handlebars to the full right position. Tip: The handlebars may also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key. Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 4. Reverse the procedure to unlock the steering.
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To shift gears, brake to a complete stop.
FEATURES AND CONTROLS All Wheel Drive (4X4) System 4X4 When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be on. When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in 4X4.
FEATURES AND CONTROLS All Wheel Drive (4X4) System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4. If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction.
FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission. The instrument cluster measures distance in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 20 for additional information.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments 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 speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 20. Tip: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles or kilometers traveled by the vehicle. Trip Meter Mode The trip meter records the miles or kilometers traveled by the vehicle on each trip if it's reset before each trip.
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 movement 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.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode 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. The service interval is programmed at 50 hours at the factory. To enable or disable the service interval: 1. Enter the diagnostic mode. 2.
Break-In Period OPERATION 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.
OPERATION Pre-Ride Checklist Item Remarks Page Hand brake/lever travel Ensure proper operation 81 Foot brake Ensure proper operation 81 Brake fluid Ensure proper level 81 Passenger seat latch Ensure latch is secure 29 Front suspension Inspect, lubricate if necessary 65 Rear suspension Inspect, lubricate if necessary 65 Steering/steering lock Unlock the steering; ensure free operation 28 Steering Ensure free operation - Tires Inspect condition and pressure 87 Wheels/fasteners
Starting the Engine OPERATION Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 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.
OPERATION Starting the Engine 8. Move the engine stop switch to RUN. Do not press the throttle while starting the engine. 9. 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. 10. If the engine does not start, release the starter and wait five seconds. 11. Repeat steps 9 and 10 until the engine starts. Operating the vehicle immediately after starting could cause engine damage.
Cold Weather Operation OPERATION Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the oil tank, which can lead to engine damage. Any condensation must be drained. Always operate the engine long enough to reach operating temperature, which reduces condensation.
OPERATION Driving Procedures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 42 Wear protective riding gear. See page 8. Perform the pre-ride inspection. See page 38. Place the transmission in PARK. Mount the vehicle from the left side. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. Start the engine and allow it to warm up. Apply the brakes. Shift the transmission into gear. Check your surroundings and determine your path of travel. Release the brakes.
Turning the Vehicle OPERATION 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 3. Never turn quickly when carrying a passenger or cargo. 4.
OPERATION Driving with a Passenger Never allow anyone under 16 years of age to operate this vehicle. Never allow anyone under 12 years of age to ride as a passenger on this 2-up vehicle. Never carry more than one passenger on this 2-up vehicle. 1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles. 2. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 8. 3.
Driving with a Passenger OPERATION 6. Mount the vehicle from the left side. 7. After the operator is seated, the passenger should mount the vehicle from the left side. Allow a passenger to ride only in the approved passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator. 8. Drive slowly. Control may be more difficult with a passenger on board. Allow more time and distance for braking. 9.
OPERATION Driving Uphill 15° Maximum Whenever traveling uphill, follow these precautions: 1. Avoid steep hills (15° maximum). 2. Avoid hills with slippery or loose surfaces. 3. Keep both feet on the footrests. 4. Shift body weight uphill. 5. Drive straight uphill. 6. Proceed at a steady rate of speed to avoid stalling. 7. Be alert. Be prepared to take emergency action. This may include dismounting quickly. 8. Never open the throttle suddenly or make sudden gear changes. 9.
Driving Uphill OPERATION If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually. 2. When fully stopped, lock the hydraulic parking brake. 3. A passenger should dismount first.The operator should dismount last. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill. 4. Use the K-turn to turn around. See page 50.
OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with slippery or loose surfaces. 3. Avoid crossing the sides of steep hills. 4. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside. 5. Shift your weight uphill. 6. Keep your feet on the footrests. 7. Steer slightly into the hill. 8.
Driving Downhill OPERATION When driving downhill, follow these precautions: 1. Avoid hills with slippery or loose surfaces. 2. Never drive downhill at high speed. Slow down. 3. Drive straight downhill. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side. 15° Maximum 4. Shift your weight rearward. 5. Apply the brakes slightly to aid in slowing. Always follow the procedures outlined in this manual for driving downhill and for braking on hills.
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. 2. 3. 4. Stop the vehicle. Keep your weight uphill. Lock the hydraulic parking brake. Leave the transmission in forward gear. Turn the engine off. A passenger should dismount first.The operator should dismount last. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill. 5.
Turning Around on a Hill (K-Turn) OPERATION 8. Lock the hydraulic parking brake. 9. Remount from the uphill side. Keep your weight uphill. A passenger should not remount until the vehicle returns to level ground. 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.
OPERATION Driving Through Water Maximum Depth Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion.
Driving Through Water OPERATION 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 98. Have the vehicle serviced by your dealer promptly. Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected.
OPERATION Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Engage 4X4 before wheels begin to lose traction. 3. Be alert. 4. Watch the trail. 5. Avoid quick, sharp turns. 6. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. 7. Never apply the brakes during a skid.
Driving Over Obstacles 1. 2. 3. 4. 5. OPERATION Always check for obstacles before operating in a new area. Be alert. Watch the terrain. Use extra caution. Never operate over large obstacles. Avoid hazards such as logs, rocks and low branches. Always have a passenger dismount before operating over an obstacle. Always follow the procedures outlined in this manual for operating over obstacles.
OPERATION Parking on an Incline Avoid parking on an incline. If it's unavoidable, follow these precautions: 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.
Driving in Reverse OPERATION Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle before backing. Be aware that a passenger can obstruct your view. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles. 5. Never open the throttle suddenly. 6. Do not use the override switch unless additional power is required for vehicle movement. Use with caution.
OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the vehicle warning labels. • Never exceed the stated load capacity for this vehicle. • Never carry cargo on the rear rack when operating the vehicle in the 2-up mode with a passenger.
OPERATION Hauling Cargo 2/3 1/3 Towing Loads Towing is approved OFF-ROAD ONLY. Towing a trailer on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road. Do not tow any trailer on a grade steeper than 15°. Always attach a towed load to the hitch point. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. • The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity.
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.
Periodic Maintenance Chart MAINTENANCE Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 32. Record maintenance and service in the Maintenance Log beginning on page 130. Service and adjustments are important for proper vehicle operation.
MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service Q Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Perform all services at whichever maintenance interval is reached first.
Periodic Maintenance Chart Item Maintenance Interval Recoil housing (if equipped) X Brake pad wear Q Battery Remarks (whichever comes first) Hours Calendar X Air filter, E main element MAINTENANCE Kilometers - Weekly - Inspect; replace as needed - Weekly - Drain water as needed, check often if operating in wet conditions 10 Monthly 160 Inspect periodically 20 Monthly 320 Check terminals; clean; test X Demand drive fluid 25 Monthly 400 Inspect level; change yearly X Rear gearcas
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Kilometers Q Valve clearance 100 12 M 1600 Inspect; adjust Q Fuel system/filter 100 12 M 1600 Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every 2 years X Radiator 100 12 M 1600 Inspect; clean external surfaces X Cooling hoses 100 12 M 1600 Inspect for leaks X Engine mounts 100 12 M 1600 Inspect 100 12 M 1600 Inspect Q
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Items not listed in the chart should be lubricated at the General Lubrication interval. Tip: The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.
MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation Mixing brands or using a non-recommended oil may cause serious engine damage. Always use a recommended oil.
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.
MAINTENANCE Engine Oil Oil and Filter 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 30 seconds. 4. Stop the engine. 5. Clean the area around the drain plug. 6. Place a drain pan under the oil tank. 7. Remove the drain plug. 8. Drain the oil. Drain Plug Screen Fitting New Sealing Washer 9. Clean the drain plug.
Engine Oil MAINTENANCE Oil and Filter Change 11. Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank. Clean the fitting. Tip: The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape. 12. Reinstall the screen fitting and rotate the fitting clockwise a Alignment Mark 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. Do not over-tighten.
MAINTENANCE Engine Oil Oil and Filter 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 71. 25. Stop the engine. Check for oil leaks. 70 Safe Range { 26. Check the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill. 27. Reinstall the dipstick. 28.
Engine Oil MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 5 cm connection between the oil tank and pump inlet has been disconnected. 1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the Clamp vent line's pressure relief slit. Pressure 2. Start the engine. Allow it to idle Relief Slit for 10-20 seconds. 3. Remove the vent line clamp.
MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 120 for the part numbers of Polaris products. Transmission Oil Recommendations Lubricant Oil Change Capacity Fill Plug Torque Drain Plug Torque Premium AGL Synthetic Gearcase Lubricant 948 ml 30 N-m 30 N-m Transmission 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.
Transmission Oil MAINTENANCE Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug. 7. Reinstall the drain plug. Torque to specification. See page 72. 8. Add the recommended oil. See page 72. 9. Reinstall the fill plug. Torque to specification. See page 72. 10. Check for leaks. 11. Discard used oil properly.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Demand Drive Unit Demand Drive Plus Fluid 265 ml 11-14 N-m 15 N-m Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 120 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole threads. Fill Plug Fill Level Drain Plug Fluid Level 1.
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 74. 7. Add the recommended fluid. 8. Reinstall the fill plug. Torque to specification. 9. Check for leaks. 10. Discard used oil properly.
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/coolant 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.
Cooling System MAINTENANCE 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. 6. Secure the access door and box cover. NOTICE: Use of a non-standard pressure cap will not allow the recovery system to function properly.
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 service.
Brake Fluid MAINTENANCE Hand Brake The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. Master Cylinder Indicator Window 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View the fluid level through the indicator window (eye) on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear. 3.
MAINTENANCE Brake Fluid Foot Brake The foot brake fluid reservoir is located under the front box. The brake fluid reservoir cap is black. 1. Position the vehicle on a level surface. 2. Open the front box cover. 3. Open the access door. 4. View the fluid level in the reservoir. 5. Remove the cap and add the recommended fluid as needed. NOTICE: Always use the recommended brake fluid. 6. Maintain the fluid level between the minimum and maximum marks. Do not overfill.
Brakes MAINTENANCE The front and rear brakes are hydraulic disc brakes, activated by applying 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 operating condition. Check more often if brakes are used heavily under normal operation. 1. Always keep brake fluid at an adequate level. See page 78. 2. Check the brake systems regularly for fluid leaks. 3.
MAINTENANCE Toe Alignment Do not attempt to adjust alignment. All steering 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 Stand straight-ahead position. 3. Tie a length of string String between two stands as shown in the illustration.
Handlebar Adjustment MAINTENANCE 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. 4.
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. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension.
Side Panel Removal MAINTENANCE 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. 5. When reinstalling side panels, align the fasteners and press firmly to secure them. Footwell Removal Screws 1. Remove the six screws on the bottom of the footwell. 2.
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 rubber 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 throttle lever back and forth while adjusting. 1.6-3.2 mm 5. Tighten the lock nut. 6.
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.
MAINTENANCE Tires Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service.
Tires MAINTENANCE Always use original equipment size and type when replacing tires. Install wheels properly. Wheel Removal/Installation 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 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.
MAINTENANCE Air Filter Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. 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. 7. Remove the filter. 8. Remove the pre-filter from the filter. Pre-Filter 9. Wash the pre-filter in soapy water. Rinse and air dry. 10.
Breather Filter/Hose MAINTENANCE The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 85. 2. Remove the hose clamps from the filter and pull the 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 damaged or clogged filter. Breather Filter 4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. 5.
MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 7.6 m X X Tip: Include rider weight on the seat when measuring. 4. Start the engine.Turn the headlight switch to high beam. 5.
Lights MAINTENANCE 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.
MAINTENANCE Lights Taillight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6. 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.
Fuse Replacement MAINTENANCE If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Tip: Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover. 2. Open the access door. 3. Remove the suspect fuse from the fuse panel. Install a new fuse with the same amperage. 4. Secure the access door. 5. Secure the box cover.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 118 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition Torque Specification New Spark Plug 12-15 N-m Previously Installed Spark Plug 23-27 N-m Spark Plug Inspection Spark plug condition is indicative of engine operation.
Spark Plugs MAINTENANCE Spark Plug Removal 1. Remove the left side panel. See page 85. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise 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 96. 6. Reinstall the spark plug cap.
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 procedure. 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. Check the air box.
Vehicle Immersion MAINTENANCE 5. Loosen the carburetor drain screw. 6. Turn the ignition key past the POSITION LIGHTS position to engage the starter. Engage the starter for only 2-3 seconds. 7. Dry the spark plug. Reinstall the plug or install a new plug. 8. Torque to specification. See page 96. 9. Tighten the carburetor drain screw. 10. Turn the fuel valve on. 11. Attempt to start the engine. If necessary, repeat the drying procedure. 12.
MAINTENANCE Carburetor Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher. Above 1800 meters the engine air/fuel mixture becomes too rich and the engine loses approximately 3% of its power for each 300 meter increase in elevation. Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient operation.
Recoil Housing (if equipped) MAINTENANCE 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 completely. 5. Reinstall the drain screw.
MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. 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. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot.
Spark Arrestor MAINTENANCE 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 repeating 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 30 cm PARK. Repeat steps 5 to 7 until no more particles are expelled. 10. Stop the engine. Allow the arrestor to cool. 11.
MAINTENANCE PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a 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.
PVT System MAINTENANCE 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. Tip: Do not hold the throttle wide open for more than 10 seconds. 6.
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.
Battery MAINTENANCE Battery Removal 1. 2. 3. 4. 5. 6. 7. Place the transmission in PARK. Disconnect the battery hold-down strap. Remove the battery cover (if equipped). On conventional batteries, remove the battery vent tube. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
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 selfdischarge.
Battery MAINTENANCE Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 107. 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 gravity to 1.270 or greater. 3. Reinstall the battery. See page 107. Make sure the positive terminal is toward the front of the vehicle.
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 manufacturer's instructions for recharging.
Cleaning and Storage MAINTENANCE Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a 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.
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 decals.
Cleaning and Storage MAINTENANCE Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" appearance for many years. Tip: 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.
MAINTENANCE Cleaning and Storage Storage Tips NOTICE: 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 111. 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.
Cleaning and Storage MAINTENANCE Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 61. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • Transmission • 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 114. 2. Remove the spark plug.
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 61. Battery Storage See pages 108-109 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.
Transporting the Vehicle MAINTENANCE 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. Turn the fuel valve off. 5. Remove the key to prevent loss during transporting. 6. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front Aarm bolt pockets.
SPECIFICATIONS SPORTSMAN 500 Touring International Maximum Weight Capacity 568 lbs. (258 kg) (includes operator, passenger, cargo, accessories) Dry Weight 791 lbs. (359 kg) Front Rack/Storage Box Capacity 90 lbs. (41 kg) Rear Rack Capacity 180 lbs. (82 kg) Receiver Hitch Tongue Capacity 120 lbs. (54.4 kg) (Rear rack capacity and tongue weight not to exceed 180 lbs. (82 kg) Hitch Towing Rating 1225 lbs. (555.7 kg) Unbraked Trailer Towing 1995 lbs. (905 kg) Capacity* Overall Length 86 in.
SPECIFICATIONS SPORTSMAN 500 Touring International Driving System Type Front Suspension Rear Suspension Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic PVT (Polaris Variable Transmission) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 8.
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2873602 2873603 2877922 2877923 2870465 2871654 2872277 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (.95 l) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (.95 l) Premium AGL Synthetic Gearcase Lube (3.
Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (5-11 kmh) Insufficient warm-up at low ambient temperatures TROUBLESHOOTING Solution Use low range. Use low range or turn around using the K-turn (see page 50). Drive at a higher speed or use low range more frequently. Warm the engine at least 5 minutes.
TROUBLESHOOTING Engine Does Not Rotate Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Solution Recharge the battery to 12.
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent l
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Overuse of choke Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Solution Refuel, cycle key to ON position thre
DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES 98/37/EC as amended (Machinery Directive) TEST / EVALUATION METHODS EN 1050 hazard analysis CD 77/311/EEC driver-perceived noise level CISPR 12:2001 EN 55012:2002 CAN/CSA-C108.
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.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES 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 f
WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR 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 limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
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 services performed.
MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 131
INDEX 0-9 D 4X4 System . . . . . . . . . . . . . . . . . 30-31 Demand Drive Fluid . . . . . . . . . . 74-75 Drive Belt Wear/Burn . . . . . . . . . . . 121 Drivetrain Break-In . . . . . . . . . . . . . . 37 Driving Downhill. . . . . . . . . . . . . . . . 49 Driving in Reverse. . . . . . . . . . . . . . . 57 Driving on a Sidehill . . . . . . . . . . . . . 48 Driving on Slippery Surfaces . . . . . . 54 Driving Over Obstacles . . . . . . . . . . . 55 Driving Procedures . . . . . . . . . . . . . .
INDEX F L Fluid Recommendations Demand Drive. . . . . . . . . . . . . . 74 Engine Oil . . . . . . . . . . . . . . . . . 66 Transmission . . . . . . . . . . . . . . . 72 Foot Brake. . . . . . . . . . . . . . . . . . . . . 25 Footwell Removal. . . . . . . . . . . . . . . 85 Front Gearcase Fluid. . . . . . . . . . 74-75 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 28 Fuel Safety . . . . . . . . . . . . . . . . . . . . 16 Fuel Tank Cap. . . . . . . . . . . . . . . . . . 28 Fuel Valve. . . . . . . . .
INDEX P S Polaris Product List . . . . . . . . . . . . 120 Polishing the Vehicle. . . . . . . . . . . 112 Position Light Lamp . . . . . . . . . . . . 93 Pre-Ride Checklist . . . . . . . . . . . . . . 38 PVT Break-In. . . . . . . . . . . . . . . . . . 37 PVT Operation. . . . . . . . . . . . . . . . . 41 PVT System . . . . . . . . . . . . . . . 104-105 Switches . . . . . . . . . . . . . . . . . . . 20-23 4X4 Switch . . . . . . . . . . . . . . . . 22 Engine Stop Switch . . . . . . . . . . 21 Hazard Warning.
