Polaris Sportsman Forest 500 Series Owner's Manual For Maintenance And Safety
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Polaris Sportsman Forest 500 Series Owner's Manual For Maintenance And Safety

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Sportsman Forest 500
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 Forest 500 Series

  • Page 1 Sportsman Forest 500 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 Before you operate this vehicle, read the owner’s manual For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9923430 Rev 01 Printed in USA *9923430...
  • Page 3 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an excit- ing line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory Motorcycles ®...
  • Page 4 POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS Industries Inc. Copyright 2011 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 5: Table Of Contents

    Specifications ......120 POLARIS Products..... 122 Troubleshooting .

  • Page 6: Introduction

    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. DANGER A DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

  • Page 7: 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 8: 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 9: Safety

    SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.
  • Page 10 SAFETY Operator Safety Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.
  • Page 11 SAFETY Operator Safety Always inspect your POLARIS vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 53. Keep both hands on the handlebars. Keep your feet on the footrests.

  • Page 12: Operator Safety

    Operator Safety If the vehicle has been involved in an accident, always have an authorized POLARIS dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems. Never operate on hills too steep for the vehicle or for your abilities.
  • Page 13 SAFETY Operator Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 26. Always follow the procedures outlined in this manual for operating over obstacles.
  • Page 14 Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify this POLARIS vehicle through improper installation or use of accessories. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached.
  • Page 15 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 16: General Alert

    POLARIS dealer to pur- chase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. The following pages repeat the information found on each label.

  • Page 17: Clutch Cover Alert

    SAFETY Safety Labels and Locations “No Passenger” Rack Warning Rack Warning Warning      Tire Pressure/ Clutch Cover Alert Load Alert “No Passenger” Warning WARNING - NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

  • Page 18: Safe Riding Gear

    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 19: 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 20: Driving Safely

    SAFETY Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 2. Apply the brakes. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.

  • Page 21: Turning The Vehicle

    SAFETY Driving Safely Turning the Vehicle 1. Before turning, activate a turn signal 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...

  • Page 22: Driving On Slippery Surfaces

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

  • Page 23: Driving Over Obstacles

    SAFETY Driving Safely Driving Over Obstacles 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. Watch the terrain. Use extra caution. 3.

  • Page 24: Driving Uphill

    SAFETY Driving Safely Driving Uphill 25 Maximum Whenever traveling uphill, follow these precautions: 1. Avoid steep hills (25 maximum). 2. Check the terrain carefully. 3. Avoid hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill. 6.
  • Page 25 SAFETY Driving Safely Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. Apply the brakes gradually. When fully stopped, lock the hydraulic parking brake.
  • Page 26 SAFETY Driving Safely Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with excessively slippery or loose surfaces. 3. Shift your weight uphill. 4.

  • Page 27: Driving Downhill

    SAFETY Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Check the terrain carefully. 2. Avoid hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.
  • Page 28 SAFETY Driving Safely Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Lock the hydraulic parking brake. 3.
  • Page 29 SAFETY Driving Safely Turning Around on a Hill (K-Turn) 8. Lock the hydraulic parking brake. 9. Remount from the uphill side. Keep your weight uphill. 10. Apply the foot brake. 11. With the transmission still in forward, start the engine. 12.

  • Page 30: Driving Through Water

    SAFETY Driving Safely Driving Through Water Maximum Depth Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements.
  • Page 31 SAFETY Driving Safely Driving Through Water If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 100. Have the vehicle serviced by your dealer promptly. If water has been ingested into the transmission (PVT), follow the pro- cedure on page 105.

  • Page 32: Parking On An Incline

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

  • Page 33: Driving In Reverse

    SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly. 4. Apply the foot brake lightly for stopping. 5.

  • Page 34: Hauling Cargo

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

  • Page 35: Towing Loads

    Never install a hitch longer than 17 cm. Never install automotive accessories on your POLARIS vehicle. Always install POLARIS-approved (or equivalent) accessories designed for use on the vehicle.

  • Page 36: Features And Controls

    FEATURES AND CONTROLS Switches All Wheel Drive Momentary High-Beam Switch Switch Winch Switch Main Key Mode/Reverse Choke Switch Override Switch Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 45. To gain additional power while operating in reverse, press the override switch before opening the throttle.

  • Page 37: Main Key Switch

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

  • Page 38: Turn Signal Switch

    FEATURES AND CONTROLS Switches Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn sig- nal light. The indicator on the pod will also flash. Return the toggle to the center posi- tion to end the signal. Horn Switch Hazard Switch...

  • Page 39: Throttle Lever

    FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle. Throttle Lever 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.

  • Page 40: 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 Foot Brake or slide while using the foot brake, reduce brake pressure.

  • Page 41: 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. 4. Release the brake lever. 5. To release the parking brake lock, squeeze and release the brake lever.

  • Page 42: Steering Lock

    FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unau- thorized use or theft of the vehicle. Tip: Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 1. Turn the handlebars to the full left position.

  • Page 43: Fuel Valve

    FEATURES AND CONTROLS Fuel Valve The fuel valve is located in the left front wheel well. OFF: For vehicle storage and when transporting. ON: For normal operation. Choke The choke assists in starting a cold engine. Refer to the engine Fuel starting procedure on page 54 Fuel...

  • Page 44: Transmission Gear Selector

    FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is Gear located on the right side of the Selector vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a com- plete stop.
  • Page 45 FEATURES AND CONTROLS Recoil Starter (if equipped) If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 54, cranking the engine with the recoil Handle starter instead of the main key switch.
  • Page 46 FEATURES AND CONTROLS All Wheel Drive (AWD) System The AWD switch may be turned on or off while the vehicle is moving. AWD will not engage until engine speed is below 3100 RPM. AWD remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in AWD.

  • Page 47: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation.

  • Page 48: Rider Information Center

    If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. 1. Gear Indicator - This...
  • Page 49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 34. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the vehicle.

  • Page 50: Diagnostic Mode

    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 51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).
  • Page 52 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference.

  • Page 53: Operation

    OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • Use extreme caution whenever handling gasoline. • Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area. • Never fill a fuel container while it's on the vehicle. Static electricity between the rack and container could cause a spark.
  • Page 54 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 gaso- line. 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 55: Pre-Ride Checklist

    Adjust for best side/rear vision Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is...

  • Page 56: Starting The Engine

    OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.

  • Page 57: Cold Weather Operation

    Water accumulation increases as outside temperature decreases. See your POLARIS dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

  • Page 58: Winch Guide

    WINCH GUIDE The responsibility for safe operation of the winch ultimately rests with you, the operator. Read and understand all safety precautions and oper- ating instructions before operating the winch. Careless operation can result in serious injury. DO NOT use the winch to lift or move people. Winch Safety Precautions 1.

  • Page 59: Winch Cable Care

    WINCH GUIDE Winch Cable Care 1. The life of a cable is directly related to the care it receives. The wire cable on a new winch (and any replacement cables) must be re- spooled under a minimum of a 100-lb. (45.4-kg) load before use. Failure to do this will result in cable damage.
  • Page 60 WINCH GUIDE Winch Preparation and Inspection DANGER Wear heavy leather gloves whenever handling cable. Do not allow the cable to slip through your hands, even with gloves on. When handling the hook, always use a handsaver. Never place fingers into the hook. Placing fingers in the hook could result in injury.

  • Page 61: Winch Rigging

    WINCH GUIDE Winch Rigging WARNING Take your time when rigging and use extra caution. Improper rigging can result in injury in addition to damage to the vehicle and equipment. Never handle the cable or rigging while another person is at the control switch. 1.

  • Page 62: Winch Operation

    WINCH GUIDE Winch Operation NOTICE: This winch is designed for intermittent use. Prolonged use may result in damage due to overheating. 1. Use common sense. 2. Take your time. 3. Think through the situation. 4. Pay attention to what is going on when you are winching. 5.
  • Page 63 WINCH GUIDE Winch Operation 13. Use as much cable as possible when pulling. Additional wraps of cable on the spool will significantly reduce the pulling power of your winch. If the winch is still not capable of pulling the load, use a snatch block.

  • Page 64: Emission Control Systems

    Do not modify the engine, intake or exhaust components, as doing so may affect compli- ance with governmental noise level requirements. Spark Arrester Your POLARIS vehicle has a spark arrester that was designed for on-road and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.

  • Page 65: 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 45. Record maintenance and service in the Maintenance Log beginning on page 131.
  • Page 66 Improperly performing the procedures marked with a  could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized POLARIS dealer perform these services. Maintenance Chart Key  Perform these operations more often for vehicles subjected to severe use.

  • Page 67: Periodic Maintenance Chart

    Monthly Inspect level; change yearly  Engine breather Monthly Inspect; clean if needed filter (if equipped)  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized POLARIS dealer perform these services. ...
  • Page 68 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Kilometers  Engine oil change Perform a break-in oil change (break-in) at one month  General Lubricate all fittings, pivots, lubrication cables, etc. Shift linkage Inspect, lubricate, adjust Steering Lubricate ...
  • Page 69 Brakes Inspect daily; adjust as  needed Headlight aim Adjust as needed  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized POLARIS dealer perform these services. ...

  • Page 70: Lubrication Guide

    Front Demand Drive Demand Drive Plus Fluid See page 77. Unit (Front Gearcase) Front Prop Shaft Yoke POLARIS Premium U-Joint Grease fittings (3 pumps maxi- Lube mum) every 800 km, before long periods of storage, or after pres- sure washing or submerging.
  • Page 71 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.

  • Page 72: Engine 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. Dipstick Wipe it dry with a clean cloth.

  • Page 73: Oil Change

    MAINTENANCE Engine Oil Oil Change Hot oil may result in serious burns. Do not allow hot oil to contact skin. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for two minutes.
  • Page 74 MAINTENANCE Engine Oil Oil Change 11. Disconnect the lower oil deliv- ery hose and remove the screen fitting from the oil tank. Clean the fitting. The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape. 12. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the Alignment Mark...
  • Page 75 MAINTENANCE Engine Oil Oil Change 20. Remove the dipstick. 21. Add 1.9 liters of recommended oil. If the sump is not drained, add about 1.6 liters initially. 22. Reinstall the dipstick. 23. Place the transmission in PARK. 24. Prime the oil pump using the procedure on page 74.

  • Page 76: Oil Pump Priming

    MAINTENANCE Engine Oil Oil Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose connection between the oil tank and 5 cm 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...

  • Page 77: Transmission Oil

    MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 122 for the part numbers of POLARIS products. Oil Recommendations Lubricant Oil Change Fill Plug Drain Plug Capacity...
  • Page 78 MAINTENANCE Transmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug. Reinstall the drain plug.

  • Page 79: Fluid Level

    Use the recommended fluid. Fill Plug Use of other fluids may result in improper operation of components. See page 122 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 80: Fluid Change

    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.
  • Page 81 Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient opera- tion. Optional jets, available from your POLARIS dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.)

  • Page 82: Cooling System

    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.

  • Page 83: Radiator Coolant

    MAINTENANCE Cooling System Radiator Coolant Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box cover. 2. Remove the access panel screws. Squeeze the outer edges of the panel inward to remove the panel.

  • Page 84: Brake Fluid

    Never operate the vehicle with spongy-feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 122 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 85: Hand Brake

    MAINTENANCE Brake Fluid Hand Brake Master Cylinder 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. Indicator Window 1. Position the vehicle on a Full level surface.
  • Page 86 MAINTENANCE Brake Fluid Foot Brake Foot Brake Fluid 1. Position the vehicle on a Reservoir level surface. 2. Remove the seat. 3. View the fluid level in the master cylinder. 4. Maintain the fluid level between the minimum and maximum marks. Do not overfill.

  • Page 87: Brake Inspections

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

  • Page 88: Toe Alignment

    2-3 mm more than the front measurement on each side of the vehicle to obtain the recommended 3-6 mm toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your POLARIS dealer for service.

  • Page 89: Handlebar Adjustment

    MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle. Handlebar Adjustment The handlebars can be adjusted for rider preference.

  • Page 90: Side Panel Removal

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

  • Page 91: 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. Boot 3.

  • Page 92: 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. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loos- ened for maintenance service.
  • Page 93 MAINTENANCE Tires Wheel Removal/Installation Always use original equipment size and type when replacing tires. Install wheels properly. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground.

  • Page 94: 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 63. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.
  • Page 95 MAINTENANCE Breather Filter/Hose The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 88. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3.

  • Page 96: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 97 MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Parking Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.
  • Page 98 MAINTENANCE Lights Taillight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counter-clockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6.

  • Page 99: Fuse Replacement

    MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a compartment.

  • Page 100: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 120 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition Torque Specification New Spark Plug 12-15 N-m Previously Installed Spark Plug 23-27 N-m Spark Plug Inspection...
  • Page 101 MAINTENANCE Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 88. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Turn the plug counter- clockwise to remove it. 4.

  • Page 102: 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 103 MAINTENANCE Vehicle Immersion 7. Dry the spark plug. Reinstall the plug or install a new plug. Torque to specification. See page 98. 8. Tighten the carburetor drain screw. 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure.

  • Page 104: Spark Arrester

    MAINTENANCE Spark Arrester Occasionally, the spark arrester may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrester. Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors. Exhaust contains poisonous carbon monoxide gas.
  • Page 105 MAINTENANCE Spark Arrester 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 106: Pvt System

    • 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 107: Pvt Drying

    MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 11 km/h Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 11 km/h High PVT Drying There may be some instances when water is accidently ingested into the PVT system.
  • Page 108 MAINTENANCE Recoil Housing (if equipped) Always drain the recoil housing after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug. Recoil Housing 1. Place the transmission in PARK. 2.
  • 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

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

  • Page 111: Battery Installation

    MAINTENANCE Battery Battery Installation 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed bat- teries do not have a vent tube). The vent tube must be free of obstructions and securely installed.

  • Page 112: 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 113 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 108. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 114 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.

  • Page 115: Cleaning And Storage

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

  • Page 116: 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 117 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 118: Storage Tips

    113. 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 recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

  • Page 119: Fluid Levels

    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 120 2. Be sure the storage area is well ventilated. 3. Cover the vehicle with a genuine POLARIS cover. Do not use plas- tic or coated materials. They do not allow enough ventilation to pre- vent condensation, and may promote corrosion and oxidation.

  • Page 121: Transporting The Vehicle

    4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets.

  • Page 122: Specifications

    Dry Sump Seat Single Seat, length 650 mm Steering System Akerman Principle, with handlebar controls Transmission Power System Shaft drive on all wheels Transmission and Gears High/Low/Neutral/Reverse/Parking Driving System Type Automatic PVT (POLARIS Variable Transmission) * Based on EU Directive 76/432/EC...

  • Page 123: Jetting Chart

    SPECIFICATIONS SPORTSMAN FOREST 500 Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 9.5" (24 cm) travel Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, Forward 10.57:1 Drive Ratio, Front 3.82:1 Tires Type Front Off Road Style, Deep Tread Design Size 25x8-12 / 5 psi (34.5 KPa) Tires Type Rear...

  • Page 124: Polaris Products

    Premium U-Joint Lube (89 ml) 2871551 Premium U-Joint Lube (414 ml) 2871329 Dielectric Grease (Nyogel Additives / Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2872893 Engine Degreaser 2871956 Loctite 565 Thread Sealant 2871076 POLARIS Battery Tender Charger...

  • Page 125: Troubleshooting

    PVT system Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Slippage from failure to...
  • Page 126 Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...
  • Page 127 Kinked or plugged fuel vent line Inspect and replace (if equipped) Incorrect fuel Replace with recommended fuel Incorrect jetting See your POLARIS dealer Possible Rich Fuel Cause Solution Fuel is very high octane Replace with lower octane fuel Overuse of choke...

  • Page 128: Engine Overheating

    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace (if equipped) Overuse of choke Inspect, clean and/or replace spark plugs Water is present in fuel Replace with fresh recommended fuel...

  • Page 129: Warranty

    WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH 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.
  • 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 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are excluded from warranty coverage in the event of a warranty claim: •...
  • Page 132 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS dealer autho- rized to repair POLARIS vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

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

  • Page 136: Index

    INDEX Accessories ....118 Demand Drive Fluid ..77-78 Age Restrictions....5 Drive Belt Wear/Burn .

  • Page 137: Index

    K-Turn ....26-27 Periodic Maintenance Chart ..63-67 Polaris Product List... . . 122 Polishing the Vehicle ... 114 Light Switch .
  • Page 138 INDEX Recoil Housing ....106 Taillight ..... . . 96 Recoil Starter .

This manual is also suitable for:

Sportsman forest 500

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