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Polaris Sportsman 9922551 Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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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.

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Summary of Contents for Polaris Sportsman 9922551

  • Page 1 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.
  • Page 2 Antes de utilizar ou andar neste veículo, leia o Manual do proprietário. Innan du hanterar eller kör detta fordon, läs Handboken. For your nearest Polaris dealer, visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 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 ®...
  • Page 5 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.

  • Page 6: Table Of Contents

    Specifications ......118 Polaris Products..... . . 120 Troubleshooting .

  • Page 7: 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.

  • Page 8: Safety Training

    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.

  • Page 9: 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.

  • Page 10: Safety

    Equipment Modifications We strongly recommend that consumers do not install on a Polaris vehi- cle any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 11 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Gloves Sleeves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 12: Eye Protection

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
  • Page 13 Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com. Never permit others to operate the vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.
  • Page 14 SAFETY Rider 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...
  • Page 15 Never turn sharply at excessive speeds, which can lead to vehicle overturn. If the vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.
  • Page 16 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°...
  • Page 17 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.
  • Page 18 SAFETY Rider 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.
  • Page 19 Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. For more information about safety, contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com.

  • Page 20: General Alert

    Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

  • Page 21: Tire Pressure/Load Alert

    SAFETY Safety Decals and Locations Reverse Override Alert Front Rack Warning Clutch Rear Rack Cover Alert 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.

  • Page 22: Rack Warning, Front And Rear

    SAFETY Safety Decals and Locations 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. (82 kg) Clutch Cover Alert NO STEP...

  • Page 23: Features And Controls

    FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Engine Stop Switch Hazard Switch Switch Headlight Main Key Switch 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.

  • Page 24: Main Key Switch

    Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position.

  • Page 25: Hazard Warning Switch

    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.
  • Page 26 Switches Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also flash. Return the toggle to the center position and push it inward to end the signal. Horn Switch Press the horn switch to sound the horn.

  • Page 27: Throttle Lever

    FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle move- ment. Release the lever to reduce engine speed and vehicle move- ment. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.

  • Page 28: Foot Brake

    FEATURES AND CONTROLS Foot Brake The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the foot Foot Brake brake, reduce brake pressure.

  • Page 29: Parking Brake

    FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze the brake lever toward the handlebar. 3. Push the parking brake lock forward to engage the lock. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever.

  • Page 30: Fuel Valve

    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.

  • Page 31: Steering Lock

    FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unau- thorized use or theft of the vehicle. 1. Turn the handlebars to the full right position. Tip: The handlebars may also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise.
  • Page 32 If the latch is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service. To remove the seat, pull the latch loop at the rear of the seat. Pull the seat upward to remove it from the vehicle.
  • Page 33 FEATURES AND CONTROLS All Wheel Drive (4X4) System 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.

  • Page 34: Engaging 4X

    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.

  • Page 35: Instrument Cluster

    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.

  • Page 36: Rider Information Center

    If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1. Gear Indicator - This indicator displays gear...
  • Page 37 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.
  • Page 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
  • Page 39 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.

  • Page 40: Operation

    Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and performance of your vehicle more than following the procedures for a proper break-in.

  • Page 41: Pre-Ride Checklist

    Ensure proper operation Adjust for best side/rear vision Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles, and...

  • Page 42: Starting The Engine

    Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1.
  • Page 43 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 maxi- mum of five seconds, releasing the key when the engine starts.

  • Page 44: Cold Weather Operation

    Any condensation must be drained. Always operate the engine long enough to reach operating temperature, which reduces condensation. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in cold weather.

  • Page 45: Driving Procedures

    Driving Procedures 1. Wear protective riding gear. See page 8. 2. Perform the pre-ride inspection. See page 38. 3. Place the transmission in PARK. 4. Mount the vehicle from the left side. 5. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars.

  • Page 46: Turning The Vehicle

    Turning the Vehicle 1. Before turning, activate a turn sig- nal to alert others of your inten- tions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while support- ing your weight on the outer foot-...

  • Page 47: Driving With A Passenger

    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.
  • Page 48 Driving with a Passenger 6. Mount the vehicle from the left side. 7. After the operator is seated, the passenger should mount the vehicle from the left side. 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.

  • Page 49: Driving Uphill

    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.
  • Page 50 Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually. 2. When fully stopped, lock the hydraulic parking brake. 3.
  • Page 51 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with slippery or loose surfaces. 3. Avoid crossing the sides of steep hills. 4.

  • Page 52: Driving Downhill

    Driving Downhill When driving downhill, follow these precautions: 1. Avoid hills with slippery or loose surfaces. 2. Never drive downhill at high speed. Slow down. 3. Drive straight downhill. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.
  • Page 53 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Lock the hydraulic parking brake. 3.
  • Page 54 Turning Around on a Hill (K-Turn) 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.

  • Page 55: Driving Through Water

    OPERATION Driving Through Water Maximum Depth Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements.
  • Page 56 OPERATION Driving Through Water If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 98. Have the vehicle serviced by your dealer promptly. Always follow the procedures outlined in this manual for driving through water.

  • Page 57: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Engage 4X4 before wheels begin to lose traction. 3.

  • Page 58: Driving Over Obstacles

    OPERATION Driving Over Obstacles 1. Always check for obstacles before operating in a new area. 2. Be alert. Watch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches. 5.

  • Page 59: Parking On An Incline

    OPERATION Parking on an Incline Avoid parking on an incline. If it's unavoidable, follow these precau- tions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Always block the rear wheels on the downhill side. 4. Turn the fuel valve off.

  • Page 60: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle before backing. Be aware that a passenger can obstruct your view. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4.

  • Page 61: Hauling Cargo

    OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the vehicle warning labels.

  • Page 62: Towing Loads

    Towing Loads Towing is approved OFF-ROAD ONLY. Towing a trailer on public roads is prohibited. See your Polaris dealer about configuring the vehi- cle to be certified to tow a trailer on-road. Do not tow any trailer on a grade steeper than 15°.

  • Page 63: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

  • Page 64: Maintenance

    MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 32. Record maintenance and service in the Maintenance Log beginning on page 130.
  • Page 65 Perform these operations more often for vehicles subjected to severe use. E Emission-related service Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

  • Page 66: Periodic Maintenance Chart

    Periodic Maintenance Chart Item Hours Calendar Kilometers Air filter, main element Recoil housing (if equipped) Brake pad wear Battery Demand drive fluid Rear gearcase oil (if equipped) Transmission oil Engine breather filter (if equipped) Engine oil change (break-in) General lubrication Carburetor float bowl Shift linkage...
  • Page 67 Spark arrestor Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Hours Calendar Kilometers 12 M 1600...

  • Page 68: Lubrication Guide

    Item Engine Oil PS-4 PLUS Performance Synthetic 2W-50 Brake Fluid DOT 4 Only Transmission Oil Polaris AGL Synthetic Gearcase Lube Demand Drive Demand Drive Plus Fluid Fluid (Front Gearcase) Front Prop Shaft Polaris Premium U-Joint...

  • Page 69: Oil Recommendations

    Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 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 tempera-...

  • Page 70: Oil Level

    Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Remove the dipstick. Wipe it dry with a clean cloth.

  • Page 71: Engine Oil

    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.
  • Page 72 Engine Oil Oil and Filter Change 11. Disconnect the lower oil deliv- ery hose and remove the screen fitting from the oil tank. Clean the fitting. Tip: The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape. 12.
  • Page 73 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.
  • Page 74 Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

  • Page 75: Transmission Oil

    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 Premium AGL Synthetic Gearcase Lubricant Transmission Oil Level 1.

  • Page 76: Transmission Oil Change

    Transmission Oil Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug.

  • Page 77: Fluid Level

    Use the recommended fluid. Fill Plug 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 Fill Level threads. Drain Plug Fluid Level 1.
  • Page 78 Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. Drain the fluid into a drain pan. 5. Clean the drain plug. 6.

  • Page 79: Cooling System

    Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is premixed and ready to use. Do not dilute with water. See page 120 for the part num- bers of Polaris products.

  • Page 80: Radiator Coolant

    Cooling System Radiator Coolant Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box cover. 2. Open the access door. 3. Remove the radiator pressure cap. 4. If coolant is not visible, slowly add coolant through the radiator filler neck.

  • Page 81: Brake Fluid

    Never operate the vehicle with spongy-feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 120 for the part numbers of Polaris products. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
  • Page 82 Brake Fluid Hand Brake The master cylinder is located on the left handle- bar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight.
  • Page 83 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.

  • Page 84: Brake Inspections

    Brakes The front and rear brakes are hydraulic disc brakes, activated by apply- ing the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition.

  • Page 85: Toe Alignment

    3-6 mm toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your Polaris dealer for ser- vice. Stand...

  • Page 86: Handlebar Adjustment

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts.

  • Page 87: Steering Assembly

    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...

  • Page 88: Side Panel Removal

    Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it.

  • Page 89: Throttle Cable Freeplay

    MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3.

  • Page 90: Tire Tread Depth

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth 3 mm Always replace tires when tread depth is worn to 3 mm or less.

  • Page 91: Wheel Nut Torque Specifications

    MAINTENANCE Tires Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loos- ened for maintenance service. 122 Nm 37 Nm Cast Aluminum Steel Nut Type Nut Torque Lug Nut 122 Nm 2-Piece Flange Nut 37 Nm...
  • Page 92 Tires Always use original equipment size and type when replacing tires. Install wheels properly. Wheel Removal/Installation 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground.

  • Page 93: Air Filter

    MAINTENANCE Air Filter Always clean and replace the air and breather filters at the intervals out- lined in the Periodic Maintenance Chart beginning on page 61. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.
  • Page 94 Breather Filter/Hose 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.

  • Page 95: High Beam Adjustment

    MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 96 Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.
  • Page 97 MAINTENANCE Lights Taillight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6.

  • Page 98: Fuse Replacement

    Fuse Replacement If the engine stops or will not start, or if you experience other electrical fail- ures, a fuse may need replacement. Tip: Spare fuses are provided in a compart- ment on the top of the access door. 1. Open the front box cover. 2.

  • Page 99: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 118 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition New Spark Plug Previously Installed Spark Plug Spark Plug Inspection Spark plug condition is indicative of engine operation.
  • Page 100 Spark Plugs 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.

  • Page 101: Vehicle Immersion

    MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following pro- cedure. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected.
  • Page 102 Vehicle Immersion 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.
  • Page 103 Tip: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or PVT or engine damage. See your Polaris dealer for more information about jetting the vehicle for condi- tions in your area. Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200.
  • Page 104 Recoil Housing (if equipped) Always drain the recoil housing after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug. 1. Place the transmission in PARK. 2.

  • Page 105: Spark Arrestor

    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.
  • Page 106 Spark Arrestor 6. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves. 7. Lightly tap on the exhaust pipe with a rubber mallet while repeat- ing step 5. 8. If particles are still suspected to be in the muffler, elevate the rear of the vehicle 30 cm higher than the front.

  • Page 107: Pvt System

    • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 108: Pvt Drying

    PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Dry it out before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the drain plug. Allow the water to drain completely. Rein- stall the drain plug.
  • Page 109 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.

  • Page 110: Battery Removal

    Battery Battery Removal 1. Place the transmission in PARK. 2. Disconnect the battery hold-down strap. 3. Remove the battery cover (if equipped). 4. On conventional batteries, remove the battery vent tube. 5. Disconnect the black (negative) battery cable first. 6. Disconnect the red (positive) battery cable last. 7.

  • Page 111: Battery Storage

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge.
  • Page 112 Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 107. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 113 Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

  • Page 114: Cleaning And Storage

    Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.

  • Page 115: Polishing The Vehicle

    Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 116 Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 117: Storage Tips

    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. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 118 Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil. 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 119 2. Be sure the storage area is well ventilated. 3. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 120: Transporting The Vehicle

    Towing a Disabled Vehicle If towing the vehicle is necessary, shift the transmission into neutral for better mobility and to prevent damage to the belt. Always attach the tow rope to the frame of the Polaris vehicle.

  • Page 121: Specifications

    SPECIFICATIONS SPORTSMAN 500 Touring International Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity 90 lbs. (41 kg) Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Fuel Capacity Engine Oil Capacity...

  • Page 122: Jetting Chart

    *EBS models require no helix/spring adjustment Jetting Chart ALTITUDE Meters (Feet) 0-1800 (0-6000) 1800-3700 (6000-12000) Automatic PVT (Polaris Variable Transmission) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 8.75" (22 cm) travel Automatic EBS (Engine Braking System) w/E-Z Shift H/L/N/R/P 23.91:1 21.74:1 10.57:1...

  • Page 123: Polaris Products

    Chain Lube, Aerosol (185 ml) 2872348 Chain Lube, Aerosol (473 ml) 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2871956 Loctite 2859044 Polaris Battery Tender Engine Lubricant Coolant Grease / Specialized Lubricants Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 124: Troubleshooting

    Dry out the PVT. See page 105. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank, fuel lines or carburetor. See your dealer.
  • Page 125 Turn the fuel valve on Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Inspect, clean and/or replace spark plugs Recharge the battery to 12.8 VDC See your dealer...
  • Page 126 Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range 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...

  • Page 127: Engine Overheating

    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...

  • Page 128: 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)

  • Page 129: Warranty

    At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle- ment.
  • Page 130 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
  • Page 131 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 132 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.

  • Page 133: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE KILOMETERS TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 134: Maintenance Log

    MAINTENANCE LOG DATE KILOMETERS TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 135: Index

    INDEX 4X4 System ....30-31 Accessories ....116 Age Restrictions.

  • Page 136: Index

    Fluid Recommendations Demand Drive....74 Engine Oil ....66 Transmission ....72 Foot Brake.
  • Page 137 INDEX Polaris Product List ... . 120 Polishing the Vehicle... 112 Position Light Lamp ... . 93 Pre-Ride Checklist .

This manual is also suitable for:

2010 sportsman 500 touring international

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