Polaris 500 H.O. 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. Owner's Manual for Maintenance and Safet y Spor tsman 400 H.O. Spor tsman 500 H.O.[...]

A card containing import ant A TV safety information should be attach ed to the owner's manual on the ne xt page. If you cannot locate this card, or if it has be en removed, plea se call 1-800- 342-3764 for assistan ce. W ARNING The engine exhau st from this produ ct contains chemicals known to the S tate of California to cause cancer , birth [...]

The text is printed on 100% recycled with 40% post-co nsumer waste (PCW).[...]

For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9923790 Rev 01 Printed in USA *9923790 * W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without proper training or instruction. S at speed[...]

1 WELCOME Thank you for purch asing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www .polarisindustries.com for the la test news, new product introductions, upcoming events, career opportunit ies and more. Here at POLARIS we proudly produce an exciting line of utility and recreational[...]

2 POLARIS and SPOR TSMAN are registered trademarks of POLARIS Industries Inc. Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may resul[...]

3 T A BLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 24 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal injury ha zard. DANGER A DANGER indicates a hazardous situat[...]

5 INTRODUCTION Failure to heed the warnings and safety precautions contained in thi s manual can result in severe injury or death. A POLARIS A TV is not a toy and can be hazardous to operate . This vehicle handl es differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuver[...]

6 INTRODUCTION V e hicle Identification Numbers Record your vehicle's identification numbers an d 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 POLARI S key blank (using your key number) and mating it wi th one of your existing keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the A TV to take a training course. If you purchased a new POLARIS A TV in the United States, your dealer provided information about the authorized A TV RiderCourse sm that is available to you and y[...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort and to redu ce the chance of injury . Helmet W earing a helmet can prevent a severe head injury . Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the[...]

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 markings such as VESC 8, V -8, Z87.1, or CE. Make sure [...]

10 SAFETY Safety W arnings Failure to operate the A TV properly can resul t in a collision, loss of control, accident or overturn, which may result i n serious injury or d eath. Heed all safety warnings outlined in this section of the owner ’ s manual. See the OPERA TION section of the owner ’s manual for proper operating proce dures. Operating[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is highl y flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling g asoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- eli[...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicle without wea ring an approved helmet and protective eyewear increases the risk of a seri ous injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield). Using Alcohol or Drugs Oper[...]

13 SAFETY Safety W arnings Operating on Pavement Operating an A TV o n paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely a ffect the handling of the A TV and could result in loss of control and accident or overturn. Avoid operating the A TV on pavement. A TV tires are designed for off-road use. If it's unavo[...]

14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the footrests during o peration can reduce your abili ty to control th e vehicle or cause loss of balance and ejection from the A TV . If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. Neve[...]

15 SAFETY Safety W arnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overtu rn. • Always follow proper procedures for travel- ing down hills as describe d in the owner's manual. NOTE: A special techniqu e is required when braking while traveling do wn- hill. See page 53. • Always descend a hill[...]

16 SAFETY Safety W arnings St alling While Climbing a Hill S talling, roll ing backwards or improperly dismounting while climbing a hil l could cause an overturn. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Keep body weight up hill. • Apply the brakes. • Lock the parking brake when fully stopped. ?[...]

17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when operati ng 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 e xtra caution on rough, slippery or loose terrain. Ope[...]

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a coll ision with an obstacle or person. Always follow proper op erating procedures as outlined in this manual. See page 57. Before shifting into reverse gear , always check for obstacles or people behind the A TV . When it's safe to proc[...]

19 SAFETY Safety W arnings Operating Through Deep W ater Operating the A TV through deep or fast- flowing water could cause the tires to floa t, causing loss of control or overturn. Avoid operating the A TV through deep or fast-flowing water . If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 55): • T ra[...]

20 SAFETY Safety W arnings Operating on Frozen Bodies of W ater Operating on frozen b odies of water may re sult in seri ous injury or death if the A TV and/or the operator fall through the ice. Never operate the A T V on a frozen body of water unless you have indepen- dently verified that the ice is sufficiently thick to support the weight and mov[...]

21 SAFETY Safety Decals and Locations W arning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully . If any of the labels shown in this manual dif fer from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic [...]

22 SAFETY Safety Decals and Locations Discretionary W arning W ARNING • Never operate this A T V on HILLS steeper than 25 d egrees 25°. T o pre- vent overturn on hilly terrain, use throttle and brakes gradua lly , and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. S teering becomes difficult. T o prevent loss of [...]

23 SAFETY Safety Decals and Locations Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch guard. T o prevent serious injury , do not operate vehicle wi th guard removed . • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, whi ch can result in serious injury or deat[...]

24 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse spee d limiter system. T o gain additional wheel speed while backing, release the throttle and depress the override button. W ARNING! Pressing the override button whil e the throttle is open can cause loss of control, which may result in seri ous[...]

25 FEA TURES 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 the switch is of f. Both the main switch and the engine stop switch will shut of f all electri- cal power to the vehicle, including lights. Main Key Switch Use the mai[...]

26 FEA TURES AND CONTROLS Throttle Lever Operating an A TV wi th sticking or impr operly operating throttle controls could cause an accident. Never start or operate an A TV 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 [...]

27 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spon gy brake lever can result in loss of braking, whi ch could cause an accident. Never operat e the A TV with a spongy-fee ling brake lever . Always contact your dealer for servi ce before operating the vehicle. Squeeze the brake lever toward the handlebar to ap ply the front and rea[...]

28 FEA TURES AND CONTROLS Master Cylinder/Brake Fluid An over-full master cyl inder 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 hygroscopic, meaning it rapidly absorbs moisture from the air[...]

29 FEA TURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PA R K . 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. T o release the parking brake lock, squeeze and release the brake lever .[...]

30 FEA TURES AND CONTROLS Auxiliary Foot Brake Never back down a hill. Applying the auxi liary brake when backing down a hill may cause rear tipover, which could result in serious inj ury or death. Use caution when ap plying the auxiliary brake. Do not aggressivel y apply the auxiliary brake when going forward. The rear wheels may ski d and slide s[...]

31 FEA TURES AND CONTROLS Fuel V alve The fuel valve is located in the left front wheel well. OFF: For vehicle storage and when transporting. ON: For normal operation. Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 46 for correct choke and throttle settings during starting. Fuel Filter The in-line [...]

32 FEA TURES AND CONTROLS Automatic T r ansmission 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 T o shift gears, brake to a com- plete stop. When the engine is idling, move the lever to the desired gear . NOTICE: Shifting gears with the engin e speed[...]

33 FEA TURES AND CONTROLS All Wheel Drive (A WD) System The All Wheel Drive sy stem is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive and the A WD indicator light in the instrument cluster will be on. When in A WD, the demand drive uni[...]

34 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also includes a[...]

35 FEA TURES 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 cluster may have shut off to protect the elect[...]

36 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center St andard Modes Use the MODE button to toggle through th e 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 the miles traveled by th e A TV . T r ip Me[...]

37 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. T o 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 o enter the diagnostics mode: 1. T urn the key[...]

38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Screen V iew this screen to check battery voltage level. T achometer Screen V iew the tachometer to check engine speed. A WD Diagnostic Screen The gauge indicates whether or not current is flowing through the A WD coil (only on models with switcha[...]

39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval T o enable or disable the service interval: 1. Enter the diagnostic mode. 2. T oggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center[...]

40 FEA TURES 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. T oggle to the screen that displays either kilometers (KM) or miles (MP). 3. Press and hold[...]

41 OPERA TION Failure to operate the A TV properly can result in a collision , loss of control, accident or overturn, which may result in serious injury or dea th. 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 A TV is the first 20 hours of o[...]

42 OPERA TION 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 neces- sary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an open area tha[...]

43 OPERA TION Safe Operation Practices 1. Complete the recommended safety trai ning before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabi lities to oper - ate this vehicl e. 3. Never carry a passenger on this A TV . 4. Engine exhaust fum[...]

44 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by con- tacting your POLARIS dealer , a local riding club or local officials. Help keep ou[...]

45 OPERA TION Pre-Ride Checklist Failure to inspect and verify that the A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel Ensure proper operation 27 78 Brake fluid Ensure prope[...]

46 OPERA TION S t arting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Place the transmission in P ARK. 3. Lock the parking brake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. Sit on t[...]

47 OPERA TION S t arting the Engine 1 1. T urn the ignition key past the ON position to engage the starter . Activate the starter for a ma ximum 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 warm up for several minutes before operati[...]

48 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright with both feet on the foo trests and both hands on the handlebars. 3. Star t 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 the parking brake. 7. Slowly[...]

49 OPERA TION T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly . T o turn, steer in the direc- tion of the turn[...]

50 OPERA TION Driving on Slippery Surfaces 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 entering slippery areas. 3. Engage A WD before wheels begin to lose traction. NOTICE: Severe d[...]

51 OPERA TION Driving Uphill Braking and handling are greatly affe cted when operating in hilly ter- rain. Improper proced ure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (25° maximum). 3. Always check the terrain carefully before ascending any hill[...]

52 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommend ed. Improper procedure could cause loss of control or overturn. A void crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. Sh[...]

53 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void 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 the brakes too firmly may cause the rear wheel[...]

54 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the vehicle, or on the lef t i[...]

55 OPERA TION Driving Through W ater Y our A TV can operate through water with a maximum recom- mended depth equal to the bot- tom of the footrests. Follow these procedures when operat- ing through water: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks have gradual inclines. 3. A void operating th[...]

56 OPERA TION Driving Over Obst acles 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 haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra caution when operating on unfamiliar [...]

57 OPERA TION 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. A void turning at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override button unles[...]

58 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or tow ing cargo impr operly can alte r vehicle handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follow these precautions when hauling carg o: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO. NE[...]

59 OPERA TION Hauling Cargo Never exceed the weight capaci- ties specified for your A TV on warning labels and in the speci- fications 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. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs[...]

60 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in P ARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5. T urn the fuel valve off.[...]

61 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compli- ance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our POLARIS vehicle has a spark arrester that was tested and qual[...]

62 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the period ic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the nee[...]

63 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key W ARNING! Improperly performing th e procedur es marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services. Symbol Description  Perform these operations more often for vehicles subjected to s[...]

64 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calend[...]

65 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km)  General lubrication 50 H 3 M 500 (800) Lubricate a ll fittings, pivots, cables, etc. Carburetor float bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage D E Throttle Cable/ Release Switch 50 H 6 M 500 ([...]

66 MAINTENANCE Periodic Maintenance Chart  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) D Clutches (drive and driven) 100 H 12 M 1000 (1600) Inspec[...]

67 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 62. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will be needed[...]

68 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 i s not used. Always use 2W -50 oil. Follow the manufacturer's rec[...]

69 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the A TV . A rising oil level between checks in cool weather driving can indicate contaminants such as gas or mois- ture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately . 1. Position the vehicle on a l[...]

70 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. Star t the engine. Allow it to idle for two to three minut es. 3. Stop the engine. 4. Clean the are[...]

71 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 crank- case. 14. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring i[...]

72 MAINTENANCE 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 or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure [...]

73 MAINTENANCE T r ansmission 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 1 17 for the part numbers of POLARIS products. The fill plug is located on the left side of the A TV , under the[...]

74 MAINTENANCE T r ansmission 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. T orque to specification. 4. Add the proper amount of the recommended oil. 5. Reinstall the fill plug. T orque to specification. 6. Check for[...]

75 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 recomme nded demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 3. Reinstall the fill plug. T orque to 8-10 ft. lbs. (1 1-14 Nm). Fluid Change 1. Posi[...]

76 MAINTENANCE Cooling System The engine coolant leve l is controlled, or maintained, by the recovery system. The recovery system components are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the eng[...]

77 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintains it s 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 drained for maintenance or repair . If the recover[...]

78 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 self- adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely[...]

79 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust ti e rod alignment. All tie rod adjustments should be performe[...]

80 MAINTENANCE S teering Assembly The steering assembly of the A TV 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. W ith a firm motion, pull the [...]

81 MAINTENANCE Ti r es Operating your A TV with worn tires, impr operly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Al ways us[...]

82 MAINTENANCE Ti r es Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing t oward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower the vehicle to the ground. 6. T orque the wheel [...]

83 MAINTENANCE Air Filter 1. Remove the seat. 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 pre- filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new main[...]

84 MAINTENANCE Breather Filter/Hose The breather filter is on the hose that runs between the engine and air box. See illustration above. 1. Remove the left side panel. See page 80. 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 direction of the [...]

85 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 the access door . 1. Open the front box cover . [...]

86 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned ou t lamps promptly . Always make sure lights are adjusted properly for best visibility . Headlight Lamp Replacement When servicing a halogen lam p, don&a[...]

87 MAINTENANCE Light s High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in P ARK. 2. Measure the distance from the floor to the cente[...]

88 MAINTENANCE Light s 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 disconn ect the speedometer harnesses from the speedometer . 4. Unplug the headlamp from the wiring harness. 5. Use a smal[...]

89 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn 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. T urn the headlight harness clock- wise to secure the [...]

90 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations Refer to the specifications section beginning on page 1 18 for the recom- mended spark plug type and gap for your vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Sp ark[...]

91 MAINTENANCE Spar k P l u g s Sp ark Plug Inspection Normal Sp ark Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip [...]

92 MAINTENANCE V ehicle Immersion If your vehicle becomes immersed, ma jor engine damage can result if the machine is not thoroughly inspected. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the A TV to dry land or at th[...]

93 MAINTENANCE S p ark Arrester Failure to heed the following warni ngs 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 protec tion and leather work gloves. Do not stand behind or in fro nt of the vehicle while purgi ng. Ne[...]

94 MAINTENANCE PVT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may oc cur at a high speed. The PVT system ha s been precision balanced. Any modification will cause the system to be out of balanc[...]

95 MAINTENANCE PVT System The basic operation of the PO LARIS 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 fly- weights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly , if the engine speed de[...]

96 MAINTENANCE PVT System When T o Use Low Range and High Range PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely . Rein- stall the dra[...]

97 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery , alw ays disconnect the negative (black) ca ble first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains sul[...]

98 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover (if equipped). 3. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the A TV . Be careful not to [...]

99 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery char ging instructions on page 101 before installing the battery . 1. Ensure that the battery is fully charged. 2. Place the battery in th[...]

100 MAINTENANCE Battery Battery S torage 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 char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rechar ge as needed to maintain a full charge. Tip : Power pl[...]

101 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 98. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as nee ded to raise the specific grav- ity to 1.270 o[...]

102 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. St ate of Charge V olt age Action Charge Time (Using constant current charger @ standa rd amps specifie d on top of batt ery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-[...]

103 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer . Handlebars The handlebars can be adjusted for rider pr[...]

104 MAINTENANCE Carburetor Y our POLARIS A TV is calibrated at the factory for optimal perfor - mance at altitudes ranging from zero to 6,000 feet (1800 m) and temper- atures of +40 degrees F . (4 degrees C.) or higher . Above 6000 feet (1800 m) the engine air/fuel mixture be comes overly rich and the engine loses approximately 3% of its po wer for[...]

105 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 expo se the end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16"[...]

106 MAINTENANCE Cleaning and St orage W ashing th e V ehicle Keeping your POLARIS vehicle clean will not only improve its appear - ance but it can also extend the life of various components. NOTICE: High water pressure ma y damage components. POLARIS recommends washing the vehicle by han d or with a garden hose, using mild soap. Certain products, i[...]

107 MAINTENANCE Cleaning and St orage W ash ing the V ehicle If a high pressure water system is used for cleaning (n ot recommended), exercise extreme caution. The water may damage components and could remove paint and decals. A void directing the water stream at the follow- ing items: • Wheel bearings • Radiator • T ransmission seals •B r [...]

108 MAINTENANCE Cleaning and St orage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chr[...]

109 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps NOTICE: S tarting 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 peri od. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 106. St abilize the[...]

110 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Fluid Levels Inspect the fluid levels. Add or change flui ds as recommended in the Periodic Maintenance Chart beginning on page 62. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change every two years and any time the fluid looks dark [...]

111 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance 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 A TV wit[...]

112 MAINTENANCE T r ansporting the A TV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PA R K . 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the A TV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to [...]

113 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 54). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range more frequently .[...]

114 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breaker or blown fuse Reset the breaker/Replace fuse Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all c[...]

115 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly , St alls 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 Cause Solution Fouled or defective spark plug(s) In[...]

116 TROUBLESHOOTING Engine Stop s 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 Overuse of chok e Inspect, cl ean and/or replace spark plugs W ater is present in fuel R eplace with new fuel Fouled [...]

117 POLARIS PRODUCTS Part Number Description Engine Lub ricant 2870791 Fo gging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synth etic 2W-50 4-Cycle Oil (qt./.95 l ) 2876245 PS-4 PLUS Performance Syntheti c 2W -50 4-Cycle Oil (gal./3.8 l) Gearcase / T ransmission Lubricants 2878068 AGL PLUS T ransmission Fluid (qt./.95 l) 2878069 AGL PLUS T [...]

118 SPECIFICA TIONS * Based on EU Directive 76/432/EC SPORTSMAN 400/500 H.O. Gross V ehicle W eight 1200 lbs. (544 kg) Maximum W eight Capacity 4 85 lbs. (220 kg) (operator, car go, accessories) Dry W e ight 688 lbs. (312 kg) (400) / 696 lbs. (316 kg) (500) Fuel Capacity 4.25 gal. (16 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmission Oil Capacity[...]

119 SPECIFICA TIONS Jetting Chart Clutching Chart (400/500) Clutching Chart (500 LE) *EBS models require no helix/spring adjustment SPORTSMAN 400/500 H.O. Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, Forward 10.57:1 Drive Ratio, Front 3.82:1 T ires/Pressure, Front 25x8-12 / 5 psi (34.5 kPa) T ires/Pressure, Rear 25x10[...]

120 W A RRANTY LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of the POLARIS All T errain V ehicle (A TV) against defects in mate rial or workmanship. W arranty period will vary regionally . POLARIS also gives a one year limited warranty on the final drive chain (if equ[...]

121 W ARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear , abuse or improper handling. This warranty also does not cover any A TV that h[...]

122 W A RRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfe ctions caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; [...]

123 W ARRANTY HOW TO OBT AIN W ARRANTY SERVICE If your A TV requires warranty service, you must take it to a POLARIS dealer authorized to repair POLARIS A TVs. When requesting warranty service you must present your copy of the W arranty Registration form to the dealer . (THE COST OF TRANSPOR T A- TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).[...]

124 W A RRANTY Exported V ehicles EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from POLARIS Industries. Deale[...]

125 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Y ou must nonetheless warranty register your vehicle under your name and addr[...]

126 W A RRANTY U.S.A. EP A Emissions Limited W arranty This emissions limi ted warranty is in add ition to the POLARIS standard limi ted war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissi ons-certified vehi cle is designed, built and equipped so it conforms with applicable U.S. Enviro[...]

127 W ARRANTY U.S.A. EP A Emissions Limited W arranty The exclusive remedy for breach of this limi ted warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRAN TY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF THIS[...]

128 MAINTENANCE LOG Present this section of your manual to your dealer each time you r vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

129 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

130 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

131 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 111 Air Filte r . . . . . . . . . . . . . . . . . . . . . . 83 All Wheel Drive System . . . . . . . . . . 33 Apparel, Protective . . . . . . . . . . . . . . 12 Auxiliary Foot Brake . . . . . . . . . . . . 78 AWD Switch . . . . . . . . . . . . . . . . 24, 33 AWD System . . . . . . . . . .[...]

132 INDEX G Gasoline Handling . . . . . . . . . . . . . . 11 Gear Selector . . . . . . . . . . . . . . . . . . 32 Gloves . . . . . . . . . . . . . . . . . . . . . . . . 9 H Hand Brake . . . . . . . . . . . . . . . . . . . 78 Handlebar Adjustment . . . . . . . . . . 103 Hauling Cargo . . . . . . . . . . . . . . . 58-59 Headlight Housing Replacement [...]

133 INDEX S Safe Opera tion Practices . . . . . . . . . . 43 Safety Deca ls . . . . . . . . . . . . . . . 21-23 Safety Labels "No Passenger" Warni ng . . . . . . . 22 Age 16 Warning . . . . . . . . . . . . . . 22 Clutch Cover Warning . . . . . . . . . 23 Discretionary Warning . . . . . . . . . 21 General Warning . . . . . . . . . . . . . [...]