Gebruiksaanwijzing /service van het product Sportsman 500 HO van de fabrikant Polaris
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P antone 426C Owner's Manual for Maintenance and Safet y Read this manual carefully . It contains important safety information. This is an adult vehicle only .
A card cont aining import ant A TV safety info rmation should be att ached to the owner's ma nual on the next pa ge. If you cannot locate th is card, or if it has been remove d, please call 1 -800- 342-3764 for assistance.
The text is printed on 100% recycled with 40% post-consume r waste (PCW)..
P antone 426C W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. 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.
1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line of utility and recreati onal products.
2 POLARIS, THE W A Y OUT and SPOR TSMAN ar e registe red trademarks of Polari s Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication.
3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 24 Operation . . . . . .
4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety ale rt symbol indicates a potential persona l injury hazard.
5 INTRODUCTION Failure to hee d the warnin gs and safety precaution s contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate. This vehicle handl es differently than other vehicles, such as motorcycles and cars.
6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n 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 yo ur key number) and matin g it with one of your existing keys.
7 SAFETY Safety T raining A TV safety training is a top prior ity for Polaris. Polaris strongly encourages you and any family member s who will be riding the A TV to take a training course.
8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort an d to reduce the chan ce of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
9 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 goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equ i pment (PPE) bearing markings such as VESC 8, V -8, Z87.
10 SAFETY Safety W arnings Failure to operate the A TV properly can re sul t 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 owne r ’s manual.
11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and e xplosive under certain conditions. • Always exercise extreme cautio n whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area.
12 SAFETY Safety W arnings Protective App arel Riding in this vehicl e without wearing an approved helmet and protective eyewe ar 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 o r face shield).
13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewalks, paths, parking lot s and driveways) may adversely a ffect the handling of the A TV an d could result in loss of control and accident or overturn.
14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the foo trests during operation can reduce your a bility to contro l the vehicle o r cause loss of balance and ejection from the A TV . If the o perator's foot is not firmly planted on the footrest, it could also contact the rear wheels.
15 SAFETY Safety W arnings Descending Hill s Impr operly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hills as describ ed in the owne r's manual. NOTE: A special techn ique is required when braking while traveling down- hill.
16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, roll ing backwards or improperly dismounting while climbi ng 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.
17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, sl ippery or loose te rrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippe ry or loose terrain.
18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow prope r operating procedures as outlined in this manual. See page 57. Before shifting into reverse gear , always check for obstacles or people behind the A T V .
19 SAFETY Safety W arnings Operating Through Deep W ater Operating the A TV throug h deep or fast- flowing water could cause the tires to float, causing loss of con trol or overturn .
20 SAFETY Safety W arnings Operating on Frozen Bodies of W ater Operating on frozen bodies of water may re sult in serious inj u ry or death if the A TV and/or the ope rator fall through the ice.
21 SAFETY Safety Decals and Locations W arning labe ls have been placed on the vehicle for your protectio n. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual dif fer from the la bels on your vehicle , always read and follow the instructio ns of the labels on the vehicle.
22 SAFETY Safety Decals and Locations T ire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 5.0 psi (34.5 kPa) Rear: 5.
23 SAFETY Safety Decals and Locations Clutch Cover W arning W ARNING • Moving part s hazard und er belt-clutch gu ard. T o prevent serious injury , do not operate vehicle with guard removed.
24 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse sp eed limiter system. T o gain additional wheel speed while backing, release the throttle and depress the override button.
25 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the e ngine quickly . The engine will not start or ru n when the switch is of f. Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights.
26 FEA TURES AND CONTROLS Throttle Lever Operating an A TV wi th sticking or impr operly operating throttl e controls could cause an accident. N ever start or oper ate an A TV that has a sticking or improperly operating th rottle. Always c ontact your dealer for service before operating the vehicle.
27 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, which could cause an accident. Neve r operat e the A TV with a spongy-fee ling brake lever . Always contact your dealer for service before ope rating the vehicle.
28 FEA TURES AND CONTROLS Master Cylinde r/Br ake Fluid An over-full master cylinder may cause brake drag or brake l ock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid.
29 FEA TURES AND CONTROLS Parking Brake Locking the P ark ing Brake 1. Place the transmission in PA R K . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever .
30 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , w hich could result in seri ous injury or death. Never ba ck down a hill. Use caution when applying the auxili ary brake.
31 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 46 for correct ch oke and throttle settings during start- ing. Fuel V alve The fuel valve is located under the front storage box cover .
32 FEA TURES AND CONTROLS Automatic T r ansmission Gear Selector The transmission gear selector is located on the right side of the v ehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park T o shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear .
33 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The Al l Wheel Drive s ystem is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive and the A WD indicator light in the instrument cluster will be on.
34 FEA TURES AND CONTROLS Instrument Cluster Y our A TV 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 war ning condition exists.
35 FEA TURES 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.
36 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle thro ugh the mode op tions. The reve rse override button is also the MODE bu tton. See page 24. The transmission cannot be in reve rse wh en using this feature.
37 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when th e gauge is in the diagnostic mode. T o exit the diagnostic mode, turn th e key switch o ff an d on. Any move - ment of the tires will also cause the gauge to exit the diagnostic mode.
38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Screen V iew this screen to check battery voltage level.
39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Pr ogrammable service inte rval T o enable or disable the service interval: 1.
40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers toggle The display in the tripmeter and od ometer can be changed to display either standard or metr ic units of measurement. 1. Enter the diagnostic mode.
41 OPERA TION Failure to operate the A TV properly can result in a collision, loss of co ntrol, accident or overturn, which may result in serious injury or death . Read and understand all safety warnings outlined in the safety section of this owner ’s manual.
42 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 31. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 69. Add oil if neces- sary to maintain the level between the safe and add marks.
43 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before op erating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicl e.
44 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you r ide. Find out where the d e signated riding areas are by con- tacting your Polaris dealer , a loca l riding club or local officials.
45 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A T V before each use to make sure it's in safe operating condition.
46 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in P ARK. 3. Lock the parking br ake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged.
47 OPERA TION S t arting the Engine 1 1. T urn the ignition key past the ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the en gine starts. NOTICE: Operating the vehicle immediate ly af ter starting could cause engine damage.
48 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright with both feet on th e foo trests and both hands on the handlebars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . 5.
49 OPERA TION T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly .
50 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezin g weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas.
51 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure coul d cause loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill.
52 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proced ure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1.
53 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. Shift body weight uph ill. 3. Drive straight downhill. 4. Slow down. Excessive speed wh en traveling downhill can cause loss of control.
54 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake while keeping body weight up hill. 2. Leave the transmission in forward and shut off the engine.
55 OPERA TION Driving Through W a ter Y our A TV can operate through water with a maximum recom- mended dep th equal to the bot- tom of the footrests. Follow these procedures when operat- ing throug h water: 1. Determine water depths and current before entering water .
56 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches.
57 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid ba cking downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sharp angles.
58 OPERA TION Hauling Cargo Overloading the vehi cle or carrying o r to wing ca rgo improperly ca n alter vehicle handling and may cause loss of control or brake instability , which can re sult in serious injury or death.
59 OPERA TION Hauling Cargo Never exceed the weight capac- ities specified for your A TV on warning labels an d in the speci- fications section of this manual. Car go weight should be evenly distributed (1/3 on th e front rack and 2/3 on the rear rack) and mounted as low as possible.
60 OPERA TION Parking on an Incline A void parking on an incline if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parking br ake. 4. Always block the rear wh eels on the downhill side.
61 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.
62 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio n, adjustment and lubrication of important components are explained in the periodic ma intenance ch art.
63 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a could resu lt in component failure and cause an accid ent, wh ich may resu lt in serious inj ury or death. Always have an authorize d Pola ris dealer perform these services.
64 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever main tenance interval is reached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
65 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.
66 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
67 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 62.
68 MAINTENANCE Engine Oil Oil Recommendations Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Pola ris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil desi gned to provide the ultimate in lubrication performance and pro tection.
69 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the A TV . A rising oil level between checks in cool weather drivin g can indicate contaminants such as gas or mois- ture collecting in the crankcase. If the oil level is over the full/safe mark, chan ge the oil imm ediately .
70 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level surface. 2.
71 MAINTENANCE Oil and Filter Change 12. Place shop towels beneat h the oil filter . Using an oil filter wrench, turn the filter counter -clockwise to remove it. 13. Using a clean dry cloth, clean the filter sealing surface on the crank- case. 14. Lubricate the o-ring on the new filter with a film of fresh engine oil.
72 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must b e performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.
73 MAINTENANCE T r ansmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 62. Maintain the oil level at the bottom of the fill pl ug hole threads. W e recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant.
74 MAINTENANCE T r ansmission Oil Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain com- pletely . 4. Clean and reinstall the drain plug. T orque to 22 ft. lbs. (30 Nm). 5. Add 32 oz.
75 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Check 1. Position the vehicle on a level su rface. Remove t he fill plug. Check the fluid level. 2. Add the recomme nded deman d driv e fluid as needed to bring the level to the bottom of the fill hole threads.
76 MAINTENANCE Cooling System The engin e coolant leve l is controlled, or maintained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
77 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair .
78 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handleba r . These brakes are self- adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drop s.
79 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment.
80 MAINTENANCE S teering Assembly The steering assemb ly of the A TV should be che cked periodically for loose nuts and bo lts. If loose nuts and bolts are found, see your Polaris dealer for service before ope rating the v ehicle. Side Panel Removal 1.
81 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr operly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and cou ld cause an accident resulting in serious injury or death . Always follow all tire maintenance procedures as outlined in this manua l a nd on the labels on the vehicle.
82 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parking br ake. 3. Place the wheel on the hub with the valve stem toward the out side and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger -tighten them.
83 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre- filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry .
84 MAINTENANCE Breather Filter/Hose The breather filter is on the hose th at runs between the engine and air box. See illustration above. 1. Remove the left side panel. See page 80. 2. Remove the hose clamps from the filter and pull the filter out of the hoses.
85 MAINTENANCE F use Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replac ement. Locate and correct any short circuits that may have caused the blown fuse, then repla ce the fuse. Spare fuses are pro- vided in a compartment on the top of the ac cess door .
86 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and rep lace burned out lamps promptly . Always make sure lights are adjusted properly for best visibility .
87 MAINTENANCE Light s High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall .
88 MAINTENANCE Light s Headlight Housin g Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconn ect the speedome ter harnesses from the speedometer .
89 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headla mp. 3. Reinstall the harness assembly into the headlight assembly .
90 MAINTENANCE Spar k P l u g s S p ark Plug Recommendations Refer to the specifications section begi nning on page 1 18 for the recom- mended spark plug type and gap for your v ehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
91 MAINTENANCE Spar k P l u g s S p ark Plug Inspection Normal Spar k Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service.
92 MAINTENANCE V ehicle Immersion If your vehicle bec omes immersed, major en gine damage can resu lt if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impossi ble to take your A TV to a dealer before starting it, follow t he steps outlined below .
93 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warnings while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combusti ble materials from the a rea. We ar eye protection and leather work gloves.
94 MAINTENANCE P VT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure ma y occur at a high speed. The PVT system has been precision balanced.
95 MAINTENANCE P VT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt.
96 MAINTENANCE P VT System When T o Use Low Range and High Range P VT Drying There may be some instances w hen wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface.
97 MAINTENANCE Battery Improperly connecting or discon necting battery cables can result in an explosion and cause serious injury or death. When removing the battery , always disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last.
98 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover . 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last.
99 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinder vehicle performance. Follow the battery charging instructio ns on page 101 before installing the battery .
100 MAINTENANCE Battery Batter y S torage 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 char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recharge as needed to mainta in a full char ge.
101 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled ele ctrolyte during charging. See pa ge 98. 2. Char ge the battery with a charging output no lar ger than 1/10 of the battery’ s amp/hr rating.
102 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top of battery) 100% 12.
103 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear S pring The rear shoc k absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your Polaris de aler .
104 MAINTENANCE Carburetor Y our Polaris A TV is calibrated at th e factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F .
105 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 .
106 MAINTENANCE Cleaning and S torage W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pre ssure may damage co mponents. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap.
107 MAINTENANCE Cleaning and S torage W ash ing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution.
108 MAINTENANCE Cleaning and S torage 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.
109 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps NOTICE: S tarting the engin e during the storag e period will disturb the protective film created by fogging and damage coul d occur . Never start the engine during the stora ge period. Clean the Exterior Make any necessary re pairs and clean the vehicle as rec ommended.
110 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Fluid Levels Inspect the flu id levels. Add or change flui ds as recommended in th e Periodic Maintenance Char t beginni ng on page 62.
111 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 62. Battery Storage See pages 100-101 for storage and charging procedures.
112 MAINTENANCE T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in PA R K . 3. Lock the parking br ake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the A T V to the transporting unit securely with suitable straps or ro pe.
113 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high rang e Use low range during loading. Starting out going up a steep in cline Use low range or turn around using the K-turn (see page 54).
114 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breake r Res et the brea ker Low battery voltage Rechar ge the battery to 12.
115 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommende d fuel Incorrect ignition ti.
116 TROUBLESHOOTING Engine S top s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged f.
117 POLARIS PRODUCTS Pa r t Number Description Engine L ubricant 2870791 F ogging Oi l (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W -40 (4-Cycle) Engine Oil (qt./.95 l) 2871844 Premium 4 Synthetic 0W -40 (4-Cycle) Engine Oil (gal./3.8 l) Gearcase / T ransmis sion Lubricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt.
118 SPECIFICA TIONS * Based on EU Directiv e 76/432/EC Sportsman 500 Gross V ehicle W eight 1200 lbs. (544 kg) Maximum W eight Capacity 485 lbs. (220 kg) (operator , cargo , accessories) Dry W e ight 696 lbs. (316 kg) Fuel Capacity 4.25 gal. (16 l) Engine Oil Capacity 2 qts.
119 SPECIFICA TIONS Jetting Chart Clutching Ch art Sportsman 500 Driving System T ype Automatic PVT (Polaris V ariable T ran smission) Front Suspension MacPherson st rut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 9.5" (24 cm) travel Shift T ype Side Lever (H/L/N/R/P) Gear Reduction, Low 23.
120 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T ele phone 763-542-0500 W e, Polaris Industries Inc., dec lare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles.
121 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s.
122 W A RRANTY W ARRANTY COVE RAGE AND EXCLUSIONS: LIMIT A T IONS OF W ARRANT IES AND REMEDIES The Polaris l imited warranty exc ludes any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse o r improper handling.
123 W ARRANTY LIMIT A T IONS OF W ARRANT IES AND REMEDIES This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su rface imperfect ions caus.
124 W A RRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P A R- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY .
125 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that hav e received authorization for export from Polaris Industries.
126 W A RRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private ci tizen, to be kept and used outside of the country in which the vehicle was o riginally purchased, all warrant y coverage will be denied.
127 W ARRANTY U.S.A. EP A Emis sion s Limited W arranty This emissions limited warr anty is in additi on to the Polaris sta ndard limited warran ty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conform s with applica- ble U.
128 W A RRANTY U.S.A. EP A Emis sion s Limited W arranty The exclusive rem edy for breach of this limited warrant y shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts.
129 MAINTENANCE LOG Present this section of your ma nual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed.
130 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS.
131 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 111 Air Filt er . . . . . . . . . . . . . . . . . . . . . . 83 All Whe el Drive System . . . . . . . . . . 33 Apparel, P rotective . . . . . . . . . . . . . . 12 Auxiliary Foo t Brake . . .
132 INDEX F Fuel Valve . . . . . . . . . . . . . . . . . . . . 31 Fuse Replaceme nt . . . . . . . . . . . . . . 85 G Gasoline Handling . . . . . . . . . . . . . . 11 Gear Selector . . . . . . . . . . . . . . . . . . 32 Gloves . . . . . . . . . . . . .
133 INDEX S Safe Op eration Practi ces . . . . . . . . . . 43 Safety Decals . . . . . . . . . . . . . . . 21-23 Safety Labels "No Passenger " Warning . . . . . . . 22 Age 16 Warnin g . . . . . . . . . . . . . . 22 Clutch Cover Wa rning . . .
Een belangrijk punt na aankoop van elk apparaat Polaris Sportsman 500 HO (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
Als u nog geen Polaris Sportsman 500 HO heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens Polaris Sportsman 500 HO vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding Polaris Sportsman 500 HO leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over Polaris Sportsman 500 HO krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
In een situatie waarin je al een beziter van Polaris Sportsman 500 HO bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de Polaris Sportsman 500 HO kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met Polaris Sportsman 500 HO . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
