Owners Manual
Page 2
... time of publication. Depictions and/or procedures in this publication is expressly prohibited. All information contained within , whether whole or in this publication. Due to constant improvements in U.S.A. 2008 Sportsman 500 EFI Owner's Manual P/N 9921477 2 Printed in the design and quality of Polaris Industries Inc. No liability can be accepted for reference use only. Copyright 2007 Polaris Sales Inc. POLARIS and POLARIS...
... time of publication. Depictions and/or procedures in this publication is expressly prohibited. All information contained within , whether whole or in this publication. Due to constant improvements in U.S.A. 2008 Sportsman 500 EFI Owner's Manual P/N 9921477 2 Printed in the design and quality of Polaris Industries Inc. No liability can be accepted for reference use only. Copyright 2007 Polaris Sales Inc. POLARIS and POLARIS...
Owners Manual
Page 18
... made to the vehicle, that may change the handling characteristics of our customers and for these purposes. Equipment Modifications We are concerned for the safety of the vehicle. NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may increase the speed or power of bodily injury. Use only Polaris-approved accessories, and familiarize...
... made to the vehicle, that may change the handling characteristics of our customers and for these purposes. Equipment Modifications We are concerned for the safety of the vehicle. NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may increase the speed or power of bodily injury. Use only Polaris-approved accessories, and familiarize...
Owners Manual
Page 42
FEATURES AND CONTROLS The transmission gear selector is located on the right side of time. 42 H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the ATV is moving could cause transmission damage. Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is left unattended, always place the transmission in heavy pulling...
FEATURES AND CONTROLS The transmission gear selector is located on the right side of time. 42 H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the ATV is moving could cause transmission damage. Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is left unattended, always place the transmission in heavy pulling...
Owners Manual
Page 46
... • Vehicle speed exceeds 15 mph (24 km/h) • The throttle is open (throttle is applied) • The transmission is shifted to neutral or park 46 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatically engage when all four wheels when the vehicle descends...
... • Vehicle speed exceeds 15 mph (24 km/h) • The throttle is open (throttle is applied) • The transmission is shifted to neutral or park 46 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatically engage when all four wheels when the vehicle descends...
Owners Manual
Page 48
... the instrument cluster fails to illuminate, a battery over-voltage may have shut off to your Polaris dealer for 2.5 seconds at start-up for proper diagnosis. 1. Drive at an RPM too low to clear the warning. 6. All segments will flash, FUEL will light up . Mode Indicator 48 Fuel Gauge - This indicator serves two purposes. Gear Indicator - Service Interval/Diagnostic Mode Indicator 5. FEATURES AND CONTROLS Instrument Cluster Rider Information Center...
... the instrument cluster fails to illuminate, a battery over-voltage may have shut off to your Polaris dealer for 2.5 seconds at start-up for proper diagnosis. 1. Drive at an RPM too low to clear the warning. 6. All segments will flash, FUEL will light up . Mode Indicator 48 Fuel Gauge - This indicator serves two purposes. Gear Indicator - Service Interval/Diagnostic Mode Indicator 5. FEATURES AND CONTROLS Instrument Cluster Rider Information Center...
Owners Manual
Page 55
... Sensor Low Throttle Position Sensor High Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Air Temp Sensor Low Voltage Air Temp Sensor High Voltage Engine Coolant Temp Low Voltage Engine Coolant...
... Sensor Low Throttle Position Sensor High Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Air Temp Sensor Low Voltage Air Temp Sensor High Voltage Engine Coolant Temp Low Voltage Engine Coolant...
Owners Manual
Page 57
... better performance. Fill the fuel tank with vehicle operation and handling. 4. Do not operate at slower speeds during the break-in period. 57 See page 58. 6. PVT Break-in (Clutches/Belt) A proper break-in of a new engine and drive components will result in more efficient performance and longer life for a proper break-in the clutches and belt by operating at sustained idle. 5. Pull only light...
... better performance. Fill the fuel tank with vehicle operation and handling. 4. Do not operate at slower speeds during the break-in period. 57 See page 58. 6. PVT Break-in (Clutches/Belt) A proper break-in of a new engine and drive components will result in more efficient performance and longer life for a proper break-in the clutches and belt by operating at sustained idle. 5. Pull only light...
Owners Manual
Page 59
... transmission in an enclosed area. 1. NOTE: The starter will prevent the engine from starting the engine. 5. Repeat this procedure until the engine starts. A rising oil level could cause engine damage. Water accumulation increases as water or excess fuel in severe injury or death. Lock the parking brake. Turn the ignition key past the ON position to start again. CAUTION Operating the vehicle immediately after starting in colder weather. 59 Starting the Engine WARNING OPERATION Engine exhaust...
... transmission in an enclosed area. 1. NOTE: The starter will prevent the engine from starting the engine. 5. Repeat this procedure until the engine starts. A rising oil level could cause engine damage. Water accumulation increases as water or excess fuel in severe injury or death. Lock the parking brake. Turn the ignition key past the ON position to start again. CAUTION Operating the vehicle immediately after starting in colder weather. 59 Starting the Engine WARNING OPERATION Engine exhaust...
Owners Manual
Page 60
... accessories on the rear rack) and mounted as low as possible. If towing a load, reduce rear rack cargo weight by the amount of the owner's manual and on the vehicle, and never exceed the weight capacities outlined in serious damage to extend belt life. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on your ATV warranty. Do not obstruct the headlight beam with cargo. Always install Polaris...
... accessories on the rear rack) and mounted as low as possible. If towing a load, reduce rear rack cargo weight by the amount of the owner's manual and on the vehicle, and never exceed the weight capacities outlined in serious damage to extend belt life. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on your ATV warranty. Do not obstruct the headlight beam with cargo. Always install Polaris...
Owners Manual
Page 61
... loads high on the front rack. Vehicle speed should be centered, securely fasten the load and operate with a loaded vehicle. When handling off-centered loads that may be adversely affected, causing the vehicle to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with extra caution. CARGO WEIGHT DISTRIBUTION should never exceed 5 mph...
... loads high on the front rack. Vehicle speed should be centered, securely fasten the load and operate with a loaded vehicle. When handling off-centered loads that may be adversely affected, causing the vehicle to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with extra caution. CARGO WEIGHT DISTRIBUTION should never exceed 5 mph...
Owners Manual
Page 76
... X Air filter, pre-filter E X Air box sediment tube Coolant (if applicable) X ADC fluid (ADC models) Headlight/taillight/ work light X Air filter, E main element Recoil housing (if applicable) X Brake pad wear Q Battery X Demand drive fluid X Rear gearcase oil (if equipped) X Transmission oil X Engine breather E filter (if equipped) X Perform these services. 76 Item Maintenance Interval (whichever comes first) Hours Calendar Q Steering Remarks Miles (Km) 100 (160) 200 (320) 250 (400) 250 (400) 250 (400) 250 (400) Inspect; change yearly Inspect level; replace...
... X Air filter, pre-filter E X Air box sediment tube Coolant (if applicable) X ADC fluid (ADC models) Headlight/taillight/ work light X Air filter, E main element Recoil housing (if applicable) X Brake pad wear Q Battery X Demand drive fluid X Rear gearcase oil (if equipped) X Transmission oil X Engine breather E filter (if equipped) X Perform these services. 76 Item Maintenance Interval (whichever comes first) Hours Calendar Q Steering Remarks Miles (Km) 100 (160) 200 (320) 250 (400) 250 (400) 250 (400) 250 (400) Inspect; change yearly Inspect level; replace...
Owners Manual
Page 98
Do not service axle nuts that all nuts are torqued to specification. See your Polaris dealer. 1. Lock the parking brake. 3. Install the wheel nuts and finger-tighten them. 5. Torque the wheel nuts to the ground. 6. MAINTENANCE Tires Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in PARK. 2. lbs. (37 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've...
Do not service axle nuts that all nuts are torqued to specification. See your Polaris dealer. 1. Lock the parking brake. 3. Install the wheel nuts and finger-tighten them. 5. Torque the wheel nuts to the ground. 6. MAINTENANCE Tires Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in PARK. 2. lbs. (37 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've...
Owners Manual
Page 102
... the rear of the lamp. WARNING Poor lighting while driving can cause serious burns to pull on the connector, not on the wiring. 6. Remove the screw from the wiring harness. Lift the pod slightly while depressing the tabs at the rear of the headlight pod. 2. Headlight and taillight lenses become dirty during normal operation. Allow lamps to maintain lighting quality. Headlight Lamp Replacement 1. Turn the...
... the rear of the lamp. WARNING Poor lighting while driving can cause serious burns to pull on the connector, not on the wiring. 6. Remove the screw from the wiring harness. Lift the pod slightly while depressing the tabs at the rear of the headlight pod. 2. Headlight and taillight lenses become dirty during normal operation. Allow lamps to maintain lighting quality. Headlight Lamp Replacement 1. Turn the...
Owners Manual
Page 103
... the following procedure to the center of the headlight pod. NOTE: Include rider weight on the wall. Observe the headlight aim on the seat when measuring. 5. Start the engine.Turn the headlight switch to the desired position by turning the knob either clockwise or counterclockwise. Loosen the phillips screw located at the same height. 3. Phillips Screw 103 Lights MAINTENANCE High Beam Adjustment The...
... the following procedure to the center of the headlight pod. NOTE: Include rider weight on the wall. Observe the headlight aim on the seat when measuring. 5. Start the engine.Turn the headlight switch to the desired position by turning the knob either clockwise or counterclockwise. Loosen the phillips screw located at the same height. 3. Phillips Screw 103 Lights MAINTENANCE High Beam Adjustment The...
Owners Manual
Page 104
... is 5 1/8" (13 cm). 10. NOTE: The distance from the locking tabs. 7. Use a small screwdriver to release it from the headlight mounting tabs. 6. Pull the headlight housing up to remove the o-rings from the locking tabs. 8. Lift the pod slightly while depressing the tabs at the rear of the headlight pod. 2. Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. 5. MAINTENANCE Lights Headlight Housing Replacement 1.
... is 5 1/8" (13 cm). 10. NOTE: The distance from the locking tabs. 7. Use a small screwdriver to release it from the headlight mounting tabs. 6. Pull the headlight housing up to remove the o-rings from the locking tabs. 8. Lift the pod slightly while depressing the tabs at the rear of the headlight pod. 2. Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. 5. MAINTENANCE Lights Headlight Housing Replacement 1.
Owners Manual
Page 123
... instructions on page 74. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Apply dielectric grease to specification. 4. Oil will drain from the spark plug cavity into the hole at the...
... instructions on page 74. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Apply dielectric grease to specification. 4. Oil will drain from the spark plug cavity into the hole at the...
Owners Manual
Page 129
... engage clutch. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. Wrong or missing belt Install the recommended belt. Warm the engine at low Use low range only. Inspect clutch seals for fouled plugs or foreign material in gas tank or fuel lines. Slow/easy clutch engage- WARNING: Excessive throttle may cause loss of control and vehicle overturn. See your Polaris dealer...
... engage clutch. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. Wrong or missing belt Install the recommended belt. Warm the engine at low Use low range only. Inspect clutch seals for fouled plugs or foreign material in gas tank or fuel lines. Slow/easy clutch engage- WARNING: Excessive throttle may cause loss of control and vehicle overturn. See your Polaris dealer...
Owners Manual
Page 134
SPECIFICATIONS Sportsman 500 EFI Maximum Weight Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type Front ...
SPECIFICATIONS Sportsman 500 EFI Maximum Weight Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type Front ...
Owners Manual
Page 135
SPECIFICATIONS Sportsman 500 EFI Shift Type Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Side Lever (H/L/N/R/P) 23.91:1 16.30:1 10.49:1 3.82:1 26x8-12 / 5 psi (34.5 KPa) 26x11-12 / 5 psi (34.5 KPa) Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single...
SPECIFICATIONS Sportsman 500 EFI Shift Type Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Side Lever (H/L/N/R/P) 23.91:1 16.30:1 10.49:1 3.82:1 26x8-12 / 5 psi (34.5 KPa) 26x11-12 / 5 psi (34.5 KPa) Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single...
Owners Manual
Page 139
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to perform the warranty repair. If you have received authorization for export. Dealers may be required to obtain documentation from Polaris Industries in...
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to perform the warranty repair. If you have received authorization for export. Dealers may be required to obtain documentation from Polaris Industries in...