Polaris 500 HO International - Manuals

4 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 hazar...

5 INTRODUCTION 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.Read and understand ...

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 Operator 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 vehicle.Never oper...

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

14 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 purchase a replacement. Replacement safety labels are provided...

15 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. Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weigh...

16 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...

17 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 mark...

18 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. Check your surroundings and determine your path of travel.6. Release...

19 SAFETY Driving Safely Turning the Vehicle 1. Before turning, activate a turn signal to alert others 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...

20 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. 3. Be alert. 4. Watch the tra...

21 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. Never operate over large obstacles. 4. Avoid ...

22 SAFETY Driving Safely Driving Uphill 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. Keep your feet on the foo...

23 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 bra...

24 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. Avoid crossing the s...

25 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 ...

26 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. 1. Stop the vehicle. Keep your weight uphill.2. Lock the hydraulic parking brake.3. Leave the transmission in forward gear. Turn the eng...

27 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. Squeeze and release the brake lever to release the parkin...

28 SAFETY Driving Safely Driving Through Water 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 m...

30 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.

31 SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Avoid backing downhill.2. Always check for obsta- cles or people behind the vehicle before backing. 3. Drive slowly.4. Apply the foot brake lightly for stopping. 5. Avoid turning at sharp angles. 6. Do ...

32 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 v...

33 SAFETY Driving Safely Hauling Cargo Towing Loads Towing is approved OFF-ROAD ONLY. Operating this vehicle with a trailer on public roads is prohibited. Do not exceed the maximum capac- ities when towing. Do not tow any trailer on a grade steeper than 15 ° . Using an improper hitch or exceeding th...

34 FEATURES AND CONTROLS Switches 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. This will cancel the reverse sp...

35 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 POSITION LIGHTS ON position. Do not attach a l...

36 FEATURES AND CONTROLS Switches All Wheel Drive Switch See page 44 for all wheel drive information. 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. T...

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

39 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 bra...

40 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. 2. Insert the steering lock key and tur...

41 FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gaso- line with a minimum pump octane of 87. Do not use fuel with ethanol content greater than 10%, such as E-85 fuel. Fuel Filter The in-line fuel filter should be replaced by...

42 FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearL: Low GearN: NeutralR: ReverseP: ParkWhenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PA...

44 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 AW...

45 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...

46 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...

47 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 odomete...

48 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...

49 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 throug...

50 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...

51 OPERATION Fuel Safety 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 bet...

52 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...

53 OPERATION Pre-Ride Checklist Item Remarks Page Foot brake Ensure proper operation 38 Hand brake/lever travel Ensure proper operation 79 Brake fluid Ensure proper level 76 Front suspension Inspect, lubricate if necessary 62 Rear suspension Inspect, lubricate if necessary 62 Steering/steering lock ...

54 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. Turn the fuel valve on...

55 OPERATION Starting the Engine 7. Do not press the throttle while starting the engine. Turn the ignition key past the POSITION LIGHTS ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. 8. If the engine does not start, re...

56 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 Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operatio...

57 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 m...

58 MAINTENANCE Periodic Maintenance Chart 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 X Perform these ...

62 MAINTENANCE Lubrication Guide Always check and change fluids and lubricate greaseable compo- nents at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Items not listed in the chart should be lubri- cated at the General Lubrication interval. Item Lube Method Engine Oi...

63 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil.Polaris recommends the use of Premium 4 Synthetic 0W-40 engine oil for this engine. Premium 4 is a fully synthetic, high performance, multi- viscosity oil designed to provide the ultimate in lubrication ...

64 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...

65 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. 4. Stop the engine. 5. Clean the area around the drain...

66 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...

67 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 68. 25. Stop the engine. ...

68 MAINTENANCE Engine Oil Oil 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 pr...

69 MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole. Use the recommended oil. See page 116 for the part numbers of Polaris products. Oil Recommendations Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill ...

71 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Recommendations Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 116 for the part numbers of Polaris products.Maintain the fluid level at the bottom of the fill hole threads. Fluid Level 1...

72 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 specificat...

73 MAINTENANCE Carburetor This vehicle is calibrated at the factory for optimal performance at alti- tudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine los...

74 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/cool- an...

75 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. Open the access door. 3. Remove the radiator pressure cap.4. If coolant is not visible, slowly add coolant through the r...

76 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 m...

77 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 t...

78 MAINTENANCE Brake Fluid Foot Brake 1. Position the vehicle on a 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. Minimum Maximum

79 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. Che...

80 MAINTENANCE Toe Alignment Do not attempt to adjust tie rod alignment. All tie rod 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 le...

81 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...

82 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 four screws on...

83 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 th...

84 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.• Maintain proper tire pressure as described on the label on your vehicle and in the specifications sectio...

85 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 fr...

86 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 57.1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the seat.4. Release the air box cover clips. 5. ...

88 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 ...

89 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/Position Light La...

90 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. Reinstall all components in r...

91 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. Spare fuses are provided in a compartment on the top of the access door.1. Open the front box cover and pull open the access door. 2. Remove the suspe...

92 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 114 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...

93 MAINTENANCE Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 82. 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 p...

94 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 inspec...

98 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 c...

99 MAINTENANCE PVT System When To Use Low Range and High Range 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 ...

101 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...

102 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. Disco...

103 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 inst...

104 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed...

105 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 102. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...

106 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....

107 MAINTENANCE 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.High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, usin...

108 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• R...

109 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 suscep...

110 MAINTENANCE Cleaning and Storage Storage Tips 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 recomme...

111 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 57.• Demand drive unit (front gearcase)• Transmission• Rear gearcase (if equipped)• Brake fluid (change every two years and any ti...

112 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 57. Battery Storage See pages 104-105 for storage and charging procedures. Storage Area/Covers 1. Set t...

113 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 Polaris vehicle to the t...

114 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman 500 HO International Gross Vehicle Weight 1200 lbs. (544 kg) Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories) Dry Weight 696 lbs. (316 kg) Fuel Capacity 4.25 gal. (16 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant ...

115 SPECIFICATIONS Jetting Chart Clutching Sportsman 500 HO International Driving System Type Automatic PVT (Polaris Variable Transmission) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 9.5" (24 cm) travel Shift Type Side Lever (H/L/N/R/P) G...

116 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (.95 l) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (3.8 l) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase L...

117 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 26). Driving at low RPM or speed (5-11 km/h) Drive at a higher speed or us...

118 TROUBLESHOOTING Engine Does Not Rotate Engine Rotates, Fails to Start Engine Backfires Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Che...

119 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...

120 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) Overuse of choke Inspect, clean and/or replace spark p...

121 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. PRODUCT IDENTIFIC...

122 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR 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 par...

123 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination, for which they were not designed or not intended, including but not limited to the following items: Warranty applies to the prod...

125 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

128 INDEX A Accessories . . . . . . . . . . . . . . . . . . 112 Age Restrictions. . . . . . . . . . . . . . . . . 5 Air Filter . . . . . . . . . . . . . . . . . . . . . 86 All Wheel Drive Switch. . . . . . . . . . 36 All Wheel Drive System . . . . . . . . . 44 B Battery . . . . . . . . . . . . . . ....