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Pantone 426C
Sportsman 500 HO
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.
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WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800- 342-3764 for assistance.
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The text is printed on 100% recycled with 40% post-consumer waste (PCW).
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Pantone 426C WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER CARRY ALWAYS USE NEVER USE NEVER USE PASSENGERS AN APPROVED ON PUBLIC WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate: S without proper training or instruction. S at speeds too fast for your skills or the conditions. S on public roads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steering and increase risk of losing control. ALWAYS: S u
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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 We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your P
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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 discrep- ancies may result between the actual vehicle and the information presented in this publi- cation. Depictions and/or procedures in this publication are in
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TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 24 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Emission Control Systems . . . . . . . . . . . . . . . 61 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 113 Polaris P
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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
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INTRODUCTION WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. • Read this owner’s manual. Understand all safety
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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. Engine Serial Number #### VIN Key Number Vehicle Model Number: ___________________________________________________ Fr
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SAFETY Safety Training ATV safety training is a top priority for Polaris. Polaris strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new Polaris ATV in the United States, your dealer sm provided instruction to you about the authorized ATV RiderCourse that is available to you and your eligible family members. This training is included in the purchase price of your ATV. You were also provided with printed materials that exp
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SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Eye Protection Long Gloves Sleeves Long Pants Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, 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,
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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
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SAFETY Safety Warnings WARNING Failure to operate the ATV 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. Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV
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SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- 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 wa
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SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield). Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol
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SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops. Operating on Public Roads Operating this ATV on public streets, roads or highways could result in a co
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SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests. Turning Improperly Turning improperly could cause loss o
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SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedures for travel- ing down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling down- hill. See page 53. • Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. • Always check the terrain carefully before descending a hill. •
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SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Keep body weight uphill. • Apply the brakes. • Lock the parking brake when fully stopped. • Dismount on uphill side, or to either side if ATV is pointed straight uphill. • Turn the ATV around and remount, following the procedure described in the owner's
