Polaris 2013 ATV Sportsman 500 Tractor INTL- Manuals

5 INTRODUCTION Failure to follow the warnings in this manual can result in serious injury or death. A POLARIS Tractor is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.• Read this owner’s man...

6 INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one o...

7 SAFETY Safety Training Never operate this vehicle without proper instruction. Take a training course. For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polarisindustries.com. Read and understand your owner's manual, which includes valuable...

8 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. 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. Approved helmets in Europe, Asia and...

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 goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markin...

10 SAFETY Rider Safety 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 Tractor.Never operat...

16 SAFETY Rider Safety Never operate the Tractor on a frozen body of water. Operating on paved surfaces may affect the handling and control of the Tractor and could result in loss of control. Avoid sudden turns or swift movement of the handlebars. Always remove the ignition key when the vehicle is n...

17 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a label becomes illegible or comes off, contact your POLARIS dealer to pur-chase a replacement. Replacement safety labels are provide...

18 SAFETY Safety Labels and Locations Tire Pressure/Load Alert TIRE PRESSURE IN PSI (kPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 420 LBS. (191 kg) INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES.Read Owner's Manual for more detailed loading information. 7174877 Override Warning WAR...

19 SAFETY Safety Labels and Locations “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Clutch Cover Alert NO STEP 7173030 Rack Warning WARNING• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may ...

20 FEATURES AND CONTROLS Switches Master Light Switch The master light switch must be in the ON position to allow operation of the headlights, parking lights and taillights. Momentary High Beam Switch Press this switch with your left forefinger to activate the headlight high beam. The lights will re...

21 FEATURES AND CONTROLS Switches Main Key Switch End all electrical power to the vehicle. The LIGHTS ON position turns the headlights on. The master light switch must be on and the engine stop switch must be in the RUN position. Start the engine. The headlights are not on in this position. After st...

22 FEATURES AND CONTROLS Switches Work Light Switch The work light switch controls a light located in the pod. Use the light when additional light is needed at the front of the vehicle, but turn the work light off when driving the vehicle (on-road). Turn Signal Switch Push the toggle switch either l...

23 FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the Tractor. 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...

24 FEATURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all brake ...

25 FEATURES AND CONTROLS Seat Seat Load Adjustment Adjust the seat spring for the comfort of a lighter or heavier operator. Reach under the rear rack to access the adjuster. Tighten the spring for heavier riders. Loosen the spring for lighter riders. Use the following table to determine the best pre...

26 FEATURES AND CONTROLS Seat Seat Removal Lift the latch bar at the rear of the seat to release the latch. Tilt the seat slightly rearward to disengage the seat tabs from the rear seat base slots. Remove the seat. Make sure the seat is securely installed before operating. Seat Height Adjustment To ...

27 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine. 1. Turn the handlebars to the full right or full le...

28 FEATURES AND CONTROLS Hitches See page 124 for hitch weight capacities. Front Hitch Use the front hitch for vehicle recovery or towing only. Do not use the front hitch for any other purpose. Always remove the front hitch before operating in forward gear. Rear Hitch Hitch specifications may differ...

29 FEATURES AND CONTROLS Hitches Hitch Installation/Removal 1. Release the wire lock from the 12.7 mm pin and remove the pin. 2. Install the hitch to the receiver. 3. Install the 12.7 mm pin through the bore of both the receiver and the hitch. Secure the wire lock. Make sure the hitch assembly is se...

30 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearL: Low GearN: NeutralR: ReverseP: Park Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when...

32 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatic...

33 FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles or kilometers, as well as hours of op...

34 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg-ments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument ...

35 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. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer reco...

36 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. T...

37 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. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing throug...

38 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...

39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement. 1. Enter the diagnostic mode. 2. Toggle to the screen that displays either ...

40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes 3. The Check Engine icon will blink once, pause, then blink twice (blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will fla...

42 OPERATION Break-In Period The break-in period for your new POLARIS Tractor 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 Tractor more than following the procedure...

43 OPERATION Pre-Ride Checklist Item Remarks Page Hand brake/lever travel Ensure proper operation 91 Foot brake Ensure proper operation 91 Brake fluid Ensure proper level 91 Front suspension Inspect, lubricate if necessary 73 Rear suspension Inspect, lubricate if necessary 73 Steering/steering lock ...

44 OPERATION Starting the Engine NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK (or neutral). 3. Sit on the vehicle. 4....

45 OPERATION Cold Weather Operation Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level fre-quently. A rising oil level could indicate condensation in the bottom of the oil tank, which can lead to engine damage. Any condensa...

46 OPERATION Driving Procedures 1. Wear protective riding gear. See page 8. 2. Perform the pre-ride inspection. See page 43. 3. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 4. Start the engine and allow it to warm up. 5. Apply the brakes. 6. Shift the transmission...

47 OPERATION Turning the Vehicle 1. Before turning, activate a turn signal to alert oth-ers of your intentions. Activate the left signal before a left turn. Acti-vate 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 ...

48 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 32. 2. Avoid steep hills (25° maximum). 3. Avoid hills with slippery or loose surfaces. 4. Keep both feet on the footrests. 5. Shi...

49 OPERATION 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....

50 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with slippery or loose surfaces. 3. Avoid crossing the sides of steep hills. 4. Shift your weight uphill. ...

51 OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 32. 2. Avoid steep hills (25° maximum). 3. Avoid hills with slippery or loose surfaces. 4. Never drive downhill at high speed. Slow ...

53 OPERATION Turning Around on a Hill (K-Turn) 9. Lock the hydraulic parking brake. 10. Remount from the uphill side. Keep your weight uphill. 11. Apply the foot brake. 12. With the transmission still in forward, start the engine. 13. Squeeze and release the brake lever to release the parking brake....

54 OPERATION Driving Through Water 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 ...

56 OPERATION Driving on Slippery Surfaces Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precau...

57 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. Parking on an Incline Avoid parking on an incline. If it'...

58 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle before backing. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles. 5. Never open the thrott...

59 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 warni...

60 OPERATION Hauling Cargo Always read and understand the load distribution warning labels on the vehicle. Never exceed the weight capacities specified for this vehicle. Towing Loads Towing is approved OFF-ROAD ONLY. Operating a Tractor/trailer combination on public roads is prohibited. See your POL...

62 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. ...

63 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. 2. Inspect all cab...

64 WINCH GUIDE Winch Preparation and Inspection 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 in...

65 WINCH GUIDE Winch Rigging 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. Use a nylon sling to attach the cable to an an...

66 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. DO NOT overheat the winch ...

67 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. 14. Never pull with less than five wraps of cabl...

68 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Spark Arrester Your POLARIS vehicle has a spark arrester that was designed for on-road and off-road operatio...

69 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 ...

70 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services. Perform all services at whichever maintenance interv...

73 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 69. Items not listed in the chart should be lubricated at the General Lubrication interval.The a-arms and upper control arms are lubricated at the factor...

74 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always us...

75 MAINTENANCE Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Remove the dipstick. Wipe it dry with a clean cloth. 6. Reinstall the dipstick completely. 7. Remove the dip...

76 MAINTENANCE Engine Oil Oil and Filter Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Clean the area around the drain plug. 6. Place a drain pan under the oil tank. 7. Remove the dra...

77 MAINTENANCE 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. Seal the fitting threads with LOCTITE PST 505 or PTFE seal tape. 12. Reinstall the screen fitting and rotate the fitting clockwise a minimu...

78 MAINTENANCE Engine Oil Oil and Filter Change 20. Remove the dipstick. 21. Add 1.9 liters of recommended oil. TIP: 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 79. 25. ...

79 MAINTENANCE 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 ve...

80 MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 126 for the part numbers of POLARIS products. Transmission Oil Recommendations Transmission Oil Level 1. Position the vehicle on a level surface. 2. Place the transmi...

81 MAINTENANCE 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. 7. Reinstall the drain plug. Torque to specification. ...

82 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Recommendations Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes any of the following:• operation in ADC mode for prolonged periods• constant ADC operation on hilly or mountainous t...

83 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. Drain the fluid into a drain pan. 5. Clean the drain plug. 6. Reinstall the drain plug. Torque to specific...

84 MAINTENANCE Active Descent Control (ADC) Fluid The ADC fluid reservoir is located under the front box. The reservoir cap is yellow. NOTICE: Change the ADC fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes operation in ADC mode for prolonged periods or in environ...

86 MAINTENANCE Cooling System Any time the cooling system has been drained for maintenance or repair, replace the coolant with a fresh mixture of antifreeze and water. Drain the cooling system every two years. Add fresh coolant. POLARIS recommends the use of POLARIS Premium 60/40 anti-freeze/coolant...

87 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. 3. Remove the radiator...

88 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level ...

89 MAINTENANCE 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. 2. View the fluid level through th...

91 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. Check...

92 MAINTENANCE Toe Alignment Do not attempt to adjust alignment. All steering adjustments should be performed by an authorized POLARIS dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out. 1. Position the vehicle on a level su...

93 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. Improper a...

94 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. Footwell Removal 1. Remove the six screws on ...

95 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. Loosen the adjuster lock nut. 4. Rotate t...

96 MAINTENANCE Tires Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle...

97 MAINTENANCE Tires Wheel Removal/Installation 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 5. Remove the wheel nuts. 6. Remove the whe...

98 MAINTENANCE Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter. Air Filter Always clean and replace the air and breather filters at the intervals out-lined in the Periodic Maintenance Chart ...

99 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 94. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3. Inspect the filter for debris. Blow gently through the filter in the d...

100 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 ...

101 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 Lam...

102 MAINTENANCE Lights Taillight/Brake Light/Signal Light Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the light socket counter-clock- wise 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. Rei...

103 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical fail-ures, a fuse may need replacement. Spare fuses are provided in the rear storage box. 1. Open the front box cover. 2. Remove the access panel screws. Squeeze the outer edges of the panel...

104 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 124 for the recom-mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Spark Plug Inspection Spark plug condition is indicative of engine operation. Check the...

105 MAINTENANCE Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 94. 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. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled ...

106 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. NOTICE: If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughl...

107 MAINTENANCE Vehicle Immersion 4. Turn the ignition key past the PARKING LIGHTS position to engage the starter. Engage the starter for only 2-3 seconds. 5. Dry the spark plug. Reinstall the plug or install a new plug. 6. Torque to specification. See page 104. 7. Attempt to start the engine. If ne...

108 MAINTENANCE Spark Arrester Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind...

109 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 3...

110 MAINTENANCE PVT System Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on ...

111 MAINTENANCE 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- st...

112 MAINTENANCE Battery Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.Antidote: External : Flush with water. Internal : Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil...

113 MAINTENANCE Battery 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. Ba...

114 MAINTENANCE Battery Battery Installation 3. On conventional batteries, coat the terminals with dielectric grease or petroleum jelly. 4. Connect and tighten the red (positive) cable first. Connect and tighten the black (negative) cable last. 5. Install the battery cover (if equipped). Secure the ...

115 MAINTENANCE Battery Battery Fluid (Conventional Battery) Check the battery fluid level often. Main-tain the fluid level between the upper and lower level marks. Add only distilled water. Tap water con-tains minerals that are harmful to a battery. Battery Charging (Conventional Battery) 1. Remove...

116 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...

117 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, us...

118 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the follow-ing items: • Wheel bearings• Ra...

119 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 suscept...

120 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as...

121 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 69.• Demand drive unit (front gearcase)• ADC fluid (change every two years)• Rear gearcase (if equipped)• Transmission• Bra...

122 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 69. Battery Storage See pages 114-115 for storage and charging procedures. Storage Area/Covers 1. Set t...

123 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap and seat. 4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the Tractor to the transp...

124 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman 500 Tractor Maximum Weight Capacity 420 lbs. (191 kg) (includes operator, cargo, acces-sories, tongue weight) Dry Weight 345 kg +/- 7% based on configuration Front Rack/Storage Box Capacity 90 lbs. (41 kg)Rear Rack Capacity 180 lbs. (82 ...

126 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l) Gearcase / Transmission Lubricants 2878068 AGL PLUS Transmission Flui...

127 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range. Starting out going up a steep incline Use low range or turn around using the K-turn (see page 52). Driving at low RPM or ground speed (5-11 kmh) Drive at a higher speed...

128 TROUBLESHOOTING Engine Does Not Rotate Engine Rotates, Fails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Possible Ca...

129 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cau...

130 TROUBLESHOOTING Engine Stops 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 fuel vent line Inspect and replace (if equipped) Water is present in fuel Replace with fresh recommende...

131 WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the POLARIS Tractor against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective par...

133 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS dealer autho-rized to repair POLARIS Tractors. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS-PORTATIO...

134 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 OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

136 INDEX 0-9 4X4 System . . . . . . . . . . . . . . . . . 30-31 A Accessories . . . . . . . . . . . . . . . . . . 122Active Descent Control Fluid . . . 84-85Active Descent Control System . . . . 32ADC System . . . . . . . . . . . . . . . . . . 32Air Filter . . . . . . . . . . . . . . . . . . . . . ...