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2011 Polaris Sportsman 500 HO Owners Manual

2011 Polaris Sportsman 500 HO Manual

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2011 Polaris Sportsman 500 HO | Owners Manual - Page 1
PMS 419 Sportsman 400 H.O. Sportsman 500 H.O. for Maintenance and Safety Owner's Manual 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.
2011 Polaris Sportsman 500 HO | Owners Manual - Page 2
the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800342-3764 for assistance.
2011 Polaris Sportsman 500 HO | Owners Manual - Page 3
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
2011 Polaris Sportsman 500 HO | Owners Manual - Page 4
on hills and rough terrain and in turns. S avoid paved surfaces - pavement may seriously affect handling and control. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55
2011 Polaris Sportsman 500 HO | Owners Manual - Page 5
operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master
2011 Polaris Sportsman 500 HO | Owners Manual - Page 6
omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. The original instructions for this vehicle are in English. Other languages are provided as translations of the original
2011 Polaris Sportsman 500 HO | Owners Manual - Page 7
TABLE OF CONTENTS Introduction ...4 Safety ...7 Features and Controls ...24 Operation ...41 Emission Control Systems ...61 Maintenance ...62 Troubleshooting ...113 POLARIS Products...117 Specifications ...118 Declaration of Conformity ...120 Warranty ...121 Maintenance Log ...129 Index ...131 3
2011 Polaris Sportsman 500 HO | Owners Manual - Page 8
on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in
2011 Polaris Sportsman 500 HO | Owners Manual - Page 9
. Understand all safety warnings, precautions and operating procedures before operating a POLARIS ATV. Keep this manual with the ATV. • Never operate an ATV without proper instruction. Take a training course. • This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years
2011 Polaris Sportsman 500 HO | Owners Manual - Page 10
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 of
2011 Polaris Sportsman 500 HO | Owners Manual - Page 11
of this vehicle in your area. We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals. FOR
2011 Polaris Sportsman 500 HO | Owners Manual - Page 12
SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Eye Protection Gloves Long Pants Helmet Long Sleeves Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS
2011 Polaris Sportsman 500 HO | Owners Manual - Page 13
SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever 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
2011 Polaris Sportsman 500 HO | Owners Manual - Page 14
. Heed all safety warnings outlined in this section of the owner's manual. See the OPERATION section of the owner's manual for proper operating procedures. Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how
2011 Polaris Sportsman 500 HO | Owners Manual - Page 15
ATV before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual. 11
2011 Polaris Sportsman 500 HO | Owners Manual - Page 16
SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles
2011 Polaris Sportsman 500 HO | Owners Manual - Page 17
SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are
2011 Polaris Sportsman 500 HO | Owners Manual - Page 18
improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster
2011 Polaris Sportsman 500 HO | Owners Manual - Page 19
. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 52. Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as
2011 Polaris Sportsman 500 HO | Owners Manual - Page 20
side, or to either side if ATV is pointed straight uphill. • Turn the ATV around and remount, following the procedure described in the owner's manual. See page 54. If the ATV begins rolling downhill: • Keep body weight uphill. • Never apply engine power. • Never apply the rear brake while rolling
2011 Polaris Sportsman 500 HO | Owners Manual - Page 21
SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain. Always use extra
2011 Polaris Sportsman 500 HO | Owners Manual - Page 22
accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area
2011 Polaris Sportsman 500 HO | Owners Manual - Page 23
ATV. • Cargo should be properly distributed and securely attached. • Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. • Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. See page 59. 19
2011 Polaris Sportsman 500 HO | Owners Manual - Page 24
of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV, you and your cargo, an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but
2011 Polaris Sportsman 500 HO | Owners Manual - Page 25
hills and rough terrain and in turns • avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OPERATOR'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. WARNING • Never operate this ATV on HILLS steeper than 25 degrees 25. To prevent overturn on hilly terrain, use
2011 Polaris Sportsman 500 HO | Owners Manual - Page 26
SAFETY Safety Decals and Locations General Warning Discretionary Warning Rack Warning Age 16 Warning "No Passenger" Warning Rack Warning      Clutch Cover Warning Tire Pressure/Load Warning Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of
2011 Polaris Sportsman 500 HO | Owners Manual - Page 27
SAFETY Safety Decals and Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 7175551 Clutch Cover Warning WARNING • Moving parts hazard under belt-clutch guard. To prevent
2011 Polaris Sportsman 500 HO | Owners Manual - Page 28
FEATURES AND CONTROLS Switches Headlight Switch AWD Switch Mode/Reverse Override Switch Engine Stop Switch Main Key Switch Choke Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and
2011 Polaris Sportsman 500 HO | Owners Manual - Page 29
FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when OFF RUN OFF the switch is off. Both the main switch and the engine stop switch will shut off all electrical power to the
2011 Polaris Sportsman 500 HO | Owners Manual - Page 30
controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle
2011 Polaris Sportsman 500 HO | Owners Manual - Page 31
in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated
2011 Polaris Sportsman 500 HO | Owners Manual - Page 32
FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is
2011 Polaris Sportsman 500 HO | Owners Manual - Page 33
FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5. To release the parking brake
2011 Polaris Sportsman 500 HO | Owners Manual - Page 34
FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when
2011 Polaris Sportsman 500 HO | Owners Manual - Page 35
FEATURES AND CONTROLS Fuel Valve The fuel valve is located under the electrical access panel. OFF: For vehicle storage and when transporting. ON: For normal operation. Fuel Valve Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 46 for correct choke
2011 Polaris Sportsman 500 HO | Owners Manual - Page 36
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. Gear
2011 Polaris Sportsman 500 HO | Owners Manual - Page 37
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel AWD drive and the AWD indicator light Switch in the instrument
2011 Polaris Sportsman 500 HO | Owners Manual - Page 38
FEATURES AND CONTROLS Instrument Cluster Your ATV 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
2011 Polaris Sportsman 500 HO | Owners Manual - Page 39
= Reverse Gear 2 P = Park 2. AWD Indicator - This 9 indicator illuminates when the AWD switch 1 is in the AWD position. 3. Engine Hour Display Indicator 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is operating at an RPM
2011 Polaris Sportsman 500 HO | Owners Manual - Page 40
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 24. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records
2011 Polaris Sportsman 500 HO | Owners Manual - Page 41
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 movement of the tires will also cause the gauge to exit the diagnostic mode. To
2011 Polaris Sportsman 500 HO | Owners Manual - Page 42
the gauge. This screen is for informational purposes only. Please see your dealer for all major repairs. Programmable service interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this
2011 Polaris Sportsman 500 HO | Owners Manual - Page 43
, until either ON or OFF appears in the Rider Information Center, depending on your preference. To reset the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for 2-3 seconds, until the wrench icon flashes. Release the button
2011 Polaris Sportsman 500 HO | Owners Manual - Page 44
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
2011 Polaris Sportsman 500 HO | Owners Manual - Page 45
, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner's manual. Break-In Period The break-in period for your new POLARIS ATV is the first ten hours of operation, or the time it takes to
2011 Polaris Sportsman 500 HO | Owners Manual - Page 46
OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 31. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 69. Add oil if necessary to maintain the level between the safe and add marks. 3.
2011 Polaris Sportsman 500 HO | Owners Manual - Page 47
, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable). 6. Operate this vehicle off-road only. Never water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV, you and your cargo,
2011 Polaris Sportsman 500 HO | Owners Manual - Page 48
OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding
2011 Polaris Sportsman 500 HO | Owners Manual - Page 49
OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Item Brake system/lever travel Brake fluid Auxiliary brake
2011 Polaris Sportsman 500 HO | Owners Manual - Page 50
OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-ventilated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.
2011 Polaris Sportsman 500 HO | Owners Manual - Page 51
OPERATION Starting the Engine 11. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to
2011 Polaris Sportsman 500 HO | Owners Manual - Page 52
OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 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
2011 Polaris Sportsman 500 HO | Owners Manual - Page 53
tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The
2011 Polaris Sportsman 500 HO | Owners Manual - Page 54
OPERATION Driving on Slippery Surfaces Sideways skid Turn in direction of skid Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when
2011 Polaris Sportsman 500 HO | Owners Manual - Page 55
OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25 maximum). 3. Always
2011 Polaris Sportsman 500 HO | Owners Manual - Page 56
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2.
2011 Polaris Sportsman 500 HO | Owners Manual - Page 57
OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Avoid steep hills (25 maximum). 2. Shift body weight uphill. 3. Drive straight downhill. 4. Slow down. Excessive speed when traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually. Applying
2011 Polaris Sportsman 500 HO | Owners Manual - Page 58
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3.
2011 Polaris Sportsman 500 HO | Owners Manual - Page 59
if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 92, then see
2011 Polaris Sportsman 500 HO | Owners Manual - Page 60
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use
2011 Polaris Sportsman 500 HO | Owners Manual - Page 61
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle
2011 Polaris Sportsman 500 HO | Owners Manual - Page 62
with extra caution. Always attach the tow load to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when
2011 Polaris Sportsman 500 HO | Owners Manual - Page 63
OPERATION Hauling Cargo Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough
2011 Polaris Sportsman 500 HO | Owners Manual - Page 64
OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5. Turn the fuel valve off. 60
2011 Polaris Sportsman 500 HO | Owners Manual - Page 65
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle
2011 Polaris Sportsman 500 HO | Owners Manual - Page 66
upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed
2011 Polaris Sportsman 500 HO | Owners Manual - Page 67
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. E Emission-related
2011 Polaris Sportsman 500 HO | Owners Manual - Page 68
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service  Have an authorized POLARIS dealer perform these
2011 Polaris Sportsman 500 HO | Owners Manual - Page 69
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar  General lubrication Carburetor float bowl  Throttle Cable/ E ETC Switch  Choke cable Remarks Miles (Km) 500 (800) 500 (800) 500 (800) 500 (800) 500 (800 500 (800) Lubricate all fittings,
2011 Polaris Sportsman 500 HO | Owners Manual - Page 70
wheel bearings  Brake fluid Spark arrestor Idle speed  Toe adjustment Headlight aim  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service  Have an authorized POLARIS dealer perform these
2011 Polaris Sportsman 500 HO | Owners Manual - Page 71
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Items not listed in the chart should
2011 Polaris Sportsman 500 HO | Owners Manual - Page 72
MAINTENANCE Engine Oil Oil Recommendations Lubricant PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil Capacity 2 qts. (1.9 l) Drain Plug Torque 14-17 ft. lbs. (19-23 Nm) Always change the oil filter whenever changing oil. POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W-
2011 Polaris Sportsman 500 HO | Owners Manual - Page 73
MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the ATV. A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil
2011 Polaris Sportsman 500 HO | Owners Manual - Page 74
MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for two to three
2011 Polaris Sportsman 500 HO | Owners Manual - Page 75
MAINTENANCE Oil and Filter Change 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counter-clockwise to remove it. 13. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 14. Lubricate the o-ring on the new filter with a film of fresh
2011 Polaris Sportsman 500 HO | Owners Manual - Page 76
MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 2" connection between the oil tank and (5 cm) pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of
2011 Polaris Sportsman 500 HO | Owners Manual - Page 77
MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level at the bottom of the fill plug hole threads. See page 117 for the part numbers of POLARIS products. The fill plug is
2011 Polaris Sportsman 500 HO | Owners Manual - Page 78
MAINTENANCE Transmission Oil Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely. 3. Clean and reinstall the drain plug. Torque to specification. 4. Add the proper amount of the recommended oil. 5. Reinstall the fill
2011 Polaris Sportsman 500 HO | Owners Manual - Page 79
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. Remove the fill plug. Check the fluid level. 2. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 3. Reinstall the fill plug. Torque to 8-
2011 Polaris Sportsman 500 HO | Owners Manual - Page 80
MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding (
2011 Polaris Sportsman 500 HO | Owners Manual - Page 81
MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been
2011 Polaris Sportsman 500 HO | Owners Manual - Page 82
MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are selfadjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the
2011 Polaris Sportsman 500 HO | Owners Manual - Page 83
1/4" (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. 79
2011 Polaris Sportsman 500 HO | Owners Manual - Page 84
assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull
2011 Polaris Sportsman 500 HO | Owners Manual - Page 85
. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original PARK. Lock the parking brake. Loosen the wheel nuts slightly. WARNING! Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 5. Elevate
2011 Polaris Sportsman 500 HO | Owners Manual - Page 86
all nuts are torqued to specification. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Nut Type Lug Nut (Aluminum Wheels) Nut Torque 30 ft. lbs. (41 Nm) PLUS 1/4 TURN 2-Piece Flange Nut (Steel Wheels) 27 ft. lbs
2011 Polaris Sportsman 500 HO | Owners Manual - Page 87
MAINTENANCE Air Filter Pre-Filter 1. Remove the seat. Main Filter 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type prefilter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 5.
2011 Polaris Sportsman 500 HO | Owners Manual - Page 88
pointing in either direction. NOTICE: Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing it for service. 84
2011 Polaris Sportsman 500 HO | Owners Manual - Page 89
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 on the top of
2011 Polaris Sportsman 500 HO | Owners Manual - Page 90
the pod cover and disconnect the speedometer harnesses from the speedometer. CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing. 5. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. 6. Turn the lamp counter-clockwise
2011 Polaris Sportsman 500 HO | Owners Manual - Page 91
MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) 2" (5 cm) 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the
2011 Polaris Sportsman 500 HO | Owners Manual - Page 92
MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the
2011 Polaris Sportsman 500 HO | Owners Manual - Page 93
MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the
2011 Polaris Sportsman 500 HO | Owners Manual - Page 94
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 118 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use
2011 Polaris Sportsman 500 HO | Owners Manual - Page 95
will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion
2011 Polaris Sportsman 500 HO | Owners Manual - Page 96
fuel valve on. Drain Screw 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. 12. If water has been ingested into the PVT, follow the procedure on
2011 Polaris Sportsman 500 HO | Owners Manual - Page 97
of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Use the following procedure to periodically purge
2011 Polaris Sportsman 500 HO | Owners Manual - Page 98
PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury safe: • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on POLARIS products only. Do not install it
2011 Polaris Sportsman 500 HO | Owners Manual - Page 99
MAINTENANCE PVT System The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the
2011 Polaris Sportsman 500 HO | Owners Manual - Page 100
There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the repeat the process. 7. Take the vehicle to your dealer for service as soon as possible. 96
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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
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MAINTENANCE Battery Battery Removal 1. 2. 3. 4. 5. 6. Disconnect the battery hold-down strap. Remove the battery cover (if equipped). On conventional batteries, remove the battery vent tube. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Lift
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has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 101 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With
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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 to
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charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. 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
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MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% Charge Time Voltage 12.8-13.0 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no charge given, check in
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handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height. 4. Be sure the handlebars do
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POLARIS dealer for more information about jetting the ATV for conditions in your area. Pilot screws are sealed with metal plugs and are serviceable only by POLARIS dealers. Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is unsatisfactory
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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 rubber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut. 4. Rotate the
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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. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose,
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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. • Always
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and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the
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. See page 106. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons
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Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Support the front end of the machine so the engine is level or tilted slightly rearward. 2. Remove the spark plug. Rotate the piston to BDC and
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Chart beginning on page 62. Battery Storage See pages 100-101 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover
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MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the ATV to the transporting unit securely with suitable
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TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM
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TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Tripped circuit breaker or blown fuse Low battery voltage Loose battery connections Loose solenoid connections Solution Reset the breaker/
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TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with
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TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Overuse of choke Water is present in fuel Fouled
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POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2878068 2878069 2877922 2877923 2870465 2871654 2872277 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 PLUS
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SPECIFICATIONS SPORTSMAN 400/500 H.O. Gross Vehicle Weight Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Capacity Demand Drive Fluid Capacity Coolant Capacity Front Rack/Box Capacity Rear Rack/Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating
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SPECIFICATIONS SPORTSMAN 400/500 H.O. Shift Type Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front/Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Side Lever
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DECLARATION OF CONFORMITY POLARIS Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 April 22, 2010 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.
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WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS All Terrain Vehicle (ATV) against defects in material or workmanship. POLARIS also gives a one year limited warranty on the final drive chain (if
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for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
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WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment,
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THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
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must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle. Outside the Country where your vehicle
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it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles registered to Government officials or military personnel on assignment outside of the country
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WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it
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responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that
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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 services performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 129
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MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 130
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INDEX A Accessories ...111 Air Filter ...83 All Wheel Drive System ...33 Apparel, Protective ...12 Auxiliary Foot Brake ...78 AWD Switch...24, 33 AWD System ...33 C Coolant Bottle ...76 Coolant, Radiator ...77 Cooling System...76-77 Corrosion Removal, Chrome ...108 Crankcase Emission Control System
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...87 Lower Headlamp Replacement. . 89 Taillight/Brakelight...89 Low Beam Adjustment ...87 Low Range Use ...96 Lower Headlamp Replacement ...89 Lubrication Guide ...67 R Reverse Operation ...57 Reverse Override Switch ...24 Rider Information Center...35-40 Riding Area ...44 Riding Gear ...8-9 132
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Warning, Front and Rear . . 23 Reverse Override Warning...23 Tire Pressure/Load Warning ...22 Safety Training ...7 Safety Warnings ...10-20 Service Interval Programming ...39 Severe Use ...62 Side Panel Removal ...80 Sidehilling ...52 Signal Words...4 Spark Arrestor...93 Spark Plug Inspection ...90