Owners Manual
Page 4
... Copyright 2008 Polaris Sales Inc. No liability can be accepted for reference use only. Any reprinting or reuse of production components, some minor discrepancies may result between the actual vehicle and the information presented in U.S.A. 2009 Sportsman 500 EFI Tractor Owner's Manual P/N 9921837 ...2 All information contained within , whether whole or in this publication. Depictions and/or procedures in part, is based on the latest product information at the time of Polaris ...
... Copyright 2008 Polaris Sales Inc. No liability can be accepted for reference use only. Any reprinting or reuse of production components, some minor discrepancies may result between the actual vehicle and the information presented in U.S.A. 2009 Sportsman 500 EFI Tractor Owner's Manual P/N 9921837 ...2 All information contained within , whether whole or in this publication. Depictions and/or procedures in part, is based on the latest product information at the time of Polaris ...
Owners Manual
Page 23
...) RUN Light Switch (High/Low Beam) Use the light switch to change the headlights from high beam to the main switch. It may contact the gas tank cap when turning, causing an interruption to the PARKING LIGHTS ON position. The master light switch must be on . After starting the engine, release the key switch to the electrical system and an unexpected engine shut-down during operation. High Beam Low Beam Light Switch Engine Stop Switch 21 Start the engine...
...) RUN Light Switch (High/Low Beam) Use the light switch to change the headlights from high beam to the main switch. It may contact the gas tank cap when turning, causing an interruption to the PARKING LIGHTS ON position. The master light switch must be on . After starting the engine, release the key switch to the electrical system and an unexpected engine shut-down during operation. High Beam Low Beam Light Switch Engine Stop Switch 21 Start the engine...
Owners Manual
Page 28
... differ from vehicle capacity specifications. Remove the key. 3. Turn the handlebars to prevent unauthorized use the front hitch for towing a trailer. Hitches See page 116 for this vehicle. Front Hitch Use the front hitch for procedures. See pages 57-59 for vehicle recovery or towing only. Always remove the front hitch before starting the engine. 1. The lock must be locked in the fully turned position when the steering is locked. Do not...
... differ from vehicle capacity specifications. Remove the key. 3. Turn the handlebars to prevent unauthorized use the front hitch for towing a trailer. Hitches See page 116 for this vehicle. Front Hitch Use the front hitch for procedures. See pages 57-59 for vehicle recovery or towing only. Always remove the front hitch before starting the engine. 1. The lock must be locked in the fully turned position when the steering is locked. Do not...
Owners Manual
Page 29
... the engine speed above idle or while the vehicle is located Gear Fuel Tank Selector on the right side of both the receiver and the hitch. Stop the vehicle, release the throttle and move the shift lever to the receiver. 3. Hitches FEATURES AND CONTROLS Hitch Installation/Removal 1. Make sure the hitch assembly is secure at that the wire lock is locked when it's in PARK. Install the hitch to the desired gear. Cap H: High Gear L: Low Gear...
... the engine speed above idle or while the vehicle is located Gear Fuel Tank Selector on the right side of both the receiver and the hitch. Stop the vehicle, release the throttle and move the shift lever to the receiver. 3. Hitches FEATURES AND CONTROLS Hitch Installation/Removal 1. Make sure the hitch assembly is secure at that the wire lock is locked when it's in PARK. Install the hitch to the desired gear. Cap H: High Gear L: Low Gear...
Owners Manual
Page 30
... the 4X4 switch is controlled by the 4X4 switch. When the rear wheels regain traction, the demand drive unit will automatically engage any time the rear wheels lose traction. Always move the 4X4 switch to the length of 4X4 in 4X4. FEATURES AND CONTROLS All Wheel Drive (4X4) System The All Wheel Drive system is on. There is on ADC 4X4, the ADC system allows engine braking to all times. 28...
... the 4X4 switch is controlled by the 4X4 switch. When the rear wheels regain traction, the demand drive unit will automatically engage any time the rear wheels lose traction. Always move the 4X4 switch to the length of 4X4 in 4X4. FEATURES AND CONTROLS All Wheel Drive (4X4) System The All Wheel Drive system is on. There is on ADC 4X4, the ADC system allows engine braking to all times. 28...
Owners Manual
Page 32
... or descending a hill. FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four of the following conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 24 km/h or less • The throttle must be closed (throttle lever released) • The transmission must be in gear (high, low or...
... or descending a hill. FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four of the following conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 24 km/h or less • The throttle must be closed (throttle lever released) • The transmission must be in gear (high, low or...
Owners Manual
Page 34
... serves two purposes. Gear Indicator - Service Interval/Diagnostic Mode Indicator 5. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. This 5 3 4 6 indicator displays gear shifter position: 7 H = High Gear L = Low Gear N = Neutral R = Reverse Gear 2 P = Park 2. 4X4 Indicator - Check Engine Warning Indicator - FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the fuel tank. If this warning appears. Mode...
... serves two purposes. Gear Indicator - Service Interval/Diagnostic Mode Indicator 5. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. This 5 3 4 6 indicator displays gear shifter position: 7 H = High Gear L = Low Gear N = Neutral R = Reverse Gear 2 P = Park 2. 4X4 Indicator - Check Engine Warning Indicator - FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the fuel tank. If this warning appears. Mode...
Owners Manual
Page 42
Do not operate at full throttle or high speeds for extended periods during the first three hours of use the first two full tanks of gasoline. Fill the fuel tank with vehicle operation and handling. 4. See page 27. 2. Check the engine oil level. Select an open area that allows room to use . Perform regular checks on fluid levels, controls and areas outlined on your...
Do not operate at full throttle or high speeds for extended periods during the first three hours of use the first two full tanks of gasoline. Fill the fuel tank with vehicle operation and handling. 4. See page 27. 2. Check the engine oil level. Select an open area that allows room to use . Perform regular checks on fluid levels, controls and areas outlined on your...
Owners Manual
Page 59
... condition. Operating a Tractor/trailer combination on page 116. • SECURE ALL LOADS BEFORE OPERATING. Use extreme caution when applying brakes. Secure off -centered loads that extend over rough or hilly terrain, reduce speed, cargo and towed load to maintain stable driving conditions. • DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the rack raises the center of gravity of control or brake...
... condition. Operating a Tractor/trailer combination on page 116. • SECURE ALL LOADS BEFORE OPERATING. Use extreme caution when applying brakes. Secure off -centered loads that extend over rough or hilly terrain, reduce speed, cargo and towed load to maintain stable driving conditions. • DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the rack raises the center of gravity of control or brake...
Owners Manual
Page 64
... page 41. Item Steering Front suspension Rear suspension Tires Brake fluid level Brake lever Foot brake Brake system Passenger seat lock-out Wheels/fasteners Frame fasteners X Engine oil level X Air filter, pre-filter E X Air box sediment tube Coolant X ADC fluid Headlight/taillight - replace as needed Drain deposits when visible Check level daily, change coolant every 2 years Check level daily, add as need ed. Have an authorized Polaris dealer perform these services. Inspect; Perform all services at whichever maintenance interval is reached first...
... page 41. Item Steering Front suspension Rear suspension Tires Brake fluid level Brake lever Foot brake Brake system Passenger seat lock-out Wheels/fasteners Frame fasteners X Engine oil level X Air filter, pre-filter E X Air box sediment tube Coolant X ADC fluid Headlight/taillight - replace as needed Drain deposits when visible Check level daily, change coolant every 2 years Check level daily, add as need ed. Have an authorized Polaris dealer perform these services. Inspect; Perform all services at whichever maintenance interval is reached first...
Owners Manual
Page 65
...X Air filter, E main element X Brake pad wear Q MAINTENANCE Remarks Inspect; change yearly Inspect; replace as needed Inspect periodically Check terminals; lubricate; test Inspect level; change yearly Inspect level; Inspect, lubricate, adjust Lubricate Lubricate Lubricate Inspect; clean if needed Inspect coolant strength seasonally; replace as needed Perform a break-in ) X General lubrication Shift linkage Q Steering X Front suspension X Rear suspension E ETC switch Q Throttle cable/ E Throttle body intake duct Drive belt Cooling system X Engine oil change X Oil filter...
...X Air filter, E main element X Brake pad wear Q MAINTENANCE Remarks Inspect; change yearly Inspect; replace as needed Inspect periodically Check terminals; lubricate; test Inspect level; change yearly Inspect level; Inspect, lubricate, adjust Lubricate Lubricate Lubricate Inspect; clean if needed Inspect coolant strength seasonally; replace as needed Perform a break-in ) X General lubrication Shift linkage Q Steering X Front suspension X Rear suspension E ETC switch Q Throttle cable/ E Throttle body intake duct Drive belt Cooling system X Engine oil change X Oil filter...
Owners Manual
Page 66
... often for wear, routing, security; Inspect; clean; replace as needed Remarks X Radiator X Cooling hoses X Engine mounts Exhaust muffler/ pipe E Q Spark plug X Wiring Q Clutches (drive and driven) bearings 100 100 200 200 H 200 300 12 M 12 M 24 M 24 M 24 M 36 M - 1600 1600 3200 3200 4800 Q Front wheel Q Brake fluid Q ADC fluid 2000 (3200) Change every two years X Fuel filter E Q Spark arrestor Q Toe adjustment Headlight aim X Perform these services. 64 apply dielectric grease to connectors subjected to...
... often for wear, routing, security; Inspect; clean; replace as needed Remarks X Radiator X Cooling hoses X Engine mounts Exhaust muffler/ pipe E Q Spark plug X Wiring Q Clutches (drive and driven) bearings 100 100 200 200 H 200 300 12 M 12 M 24 M 24 M 24 M 36 M - 1600 1600 3200 3200 4800 Q Front wheel Q Brake fluid Q ADC fluid 2000 (3200) Change every two years X Fuel filter E Q Spark arrestor Q Toe adjustment Headlight aim X Perform these services. 64 apply dielectric grease to connectors subjected to...
Owners Manual
Page 94
.... 2. Start the engine.Turn the headlight switch to the left or right. The headlight should be adjusted slightly upward or downward. 1. Include rider weight on the wall. The most intense part of the headlight beam should be approximately 7.6 m from the floor to the center of the headlight and make a mark on the wall at the same height. Place the transmission in PARK. 3. Screw...
.... 2. Start the engine.Turn the headlight switch to the left or right. The headlight should be adjusted slightly upward or downward. 1. Include rider weight on the wall. The most intense part of the headlight beam should be approximately 7.6 m from the floor to the center of the headlight and make a mark on the wall at the same height. Place the transmission in PARK. 3. Screw...
Owners Manual
Page 113
... to remove it. Removing Corrosion If light rust is found on plated or painted surfaces. 2. Gently rub the affected areas with clear water. Wash chrome wheels frequently. Routinely and liberally apply a weather... resistant wax to salt or other elements can cause corrosion. 3. Read and follow the product labels and instructions. Rinse well with the steel wool until the corrosion has been removed. Polish the clean chrome wheels periodically. Chrome wheels exposed to road salt (or salt in the air...
... to remove it. Removing Corrosion If light rust is found on plated or painted surfaces. 2. Gently rub the affected areas with clear water. Wash chrome wheels frequently. Routinely and liberally apply a weather... resistant wax to salt or other elements can cause corrosion. 3. Read and follow the product labels and instructions. Rinse well with the steel wool until the corrosion has been removed. Polish the clean chrome wheels periodically. Chrome wheels exposed to road salt (or salt in the air...
Owners Manual
Page 115
... strength/fill) Fog the Engine 1. Remove the spark plug. Reinstall the caps. 5. Turn the engine over several times using electric start. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be forced in the Periodic Maintenance Chart beginning on page 61. • Demand drive unit (front gearcase) • ADC fluid (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change fluids as recommended...
... strength/fill) Fog the Engine 1. Remove the spark plug. Reinstall the caps. 5. Turn the engine over several times using electric start. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be forced in the Periodic Maintenance Chart beginning on page 61. • Demand drive unit (front gearcase) • ADC fluid (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change fluids as recommended...
Owners Manual
Page 118
.... (1.9 l) Coolant Capacity 2.7 qts. (2.5 l) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Transmission Oil Capacity 32 oz. (948 ml) Engine EH50PLE Displacement 498 cc Bore x Stroke 92mm x 75mm Alternator Output 350 w Compression Ratio 10.2:1 Fuel System Electronic Fuel Injection Ignition System Electronic Ignition Ignition Timing 10 +/- 1 BTDC @ idle Spark Plug NGK BKR6E Spark Plug Gap .035+0.0/-0.004 in. (0.9+0.0/-0.1 mm) Lubrication System Dry Sump Driving System Type Automatic PVT (Polaris Variable Transmission) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension...
.... (1.9 l) Coolant Capacity 2.7 qts. (2.5 l) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Transmission Oil Capacity 32 oz. (948 ml) Engine EH50PLE Displacement 498 cc Bore x Stroke 92mm x 75mm Alternator Output 350 w Compression Ratio 10.2:1 Fuel System Electronic Fuel Injection Ignition System Electronic Ignition Ignition Timing 10 +/- 1 BTDC @ idle Spark Plug NGK BKR6E Spark Plug Gap .035+0.0/-0.004 in. (0.9+0.0/-0.1 mm) Lubrication System Dry Sump Driving System Type Automatic PVT (Polaris Variable Transmission) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension...
Owners Manual
Page 119
SPECIFICATIONS Sportsman 500 EFI Tractor Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Parking Lights Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) w/E-Z Shift H/L/N/R/P 23.91:1 21.74:1 10.57:1 3.82:1 25x8-12 / 5 psi (34.5 kPa) 25x12.5-12 / 5 psi (34.5 kPa) All-wheel hydraulic disc All-wheel hydraulic disc Transmission park lock and hydraulic lock, all wheel 2 Hi/Lo beam on bumper (37.5 watt) 5 watts 8.26 watts 26.9 ...
SPECIFICATIONS Sportsman 500 EFI Tractor Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Parking Lights Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) w/E-Z Shift H/L/N/R/P 23.91:1 21.74:1 10.57:1 3.82:1 25x8-12 / 5 psi (34.5 kPa) 25x12.5-12 / 5 psi (34.5 kPa) All-wheel hydraulic disc All-wheel hydraulic disc Transmission park lock and hydraulic lock, all wheel 2 Hi/Lo beam on bumper (37.5 watt) 5 watts 8.26 watts 26.9 ...
Owners Manual
Page 121
... clutch seals for fouled plugs or foreign material in gas tank or fuel lines. Improper break-in Always break in mud or snow Shift the transmission to low range. Drive at a higher speed or use low range more when temperature is below 40 km/h for warm up belt 1.5 km (8 km or more frequently. See your Polaris dealer. ment Towing/pushing at least 5 minutes. TROUBLESHOOTING...
... clutch seals for fouled plugs or foreign material in gas tank or fuel lines. Improper break-in Always break in mud or snow Shift the transmission to low range. Drive at a higher speed or use low range more when temperature is below 40 km/h for warm up belt 1.5 km (8 km or more frequently. See your Polaris dealer. ment Towing/pushing at least 5 minutes. TROUBLESHOOTING...
Owners Manual
Page 131
... Fuel Filter ...90 Fuel Tank Cap...27 Fuel Valve...27 Fuse Replacement ...95 H Hitches ...26 Horn Switch ...22 Hub Tightening ...88 I Immersion ...99 Immersion Maintenance ...98 Instrument Cluster ...31-39 K Key Switch ...21 K-Turn ...50-51 L Light Switch, High/Low Beam...21 Light Switch, Master ...20 Lights ...92-94 Brake Light ...94 Front Turn Signal ...94 Headlight Lamp ...93 High Beam Adjustment ...92 Position Light Lamp ...93 Rear Turn Signal...94 Taillight...94 Low Range Use...43 Lubrication Guide ...65 G Gear Selector...27 Gloves ...9 M Maintenance...
... Fuel Filter ...90 Fuel Tank Cap...27 Fuel Valve...27 Fuse Replacement ...95 H Hitches ...26 Horn Switch ...22 Hub Tightening ...88 I Immersion ...99 Immersion Maintenance ...98 Instrument Cluster ...31-39 K Key Switch ...21 K-Turn ...50-51 L Light Switch, High/Low Beam...21 Light Switch, Master ...20 Lights ...92-94 Brake Light ...94 Front Turn Signal ...94 Headlight Lamp ...93 High Beam Adjustment ...92 Position Light Lamp ...93 Rear Turn Signal...94 Taillight...94 Low Range Use...43 Lubrication Guide ...65 G Gear Selector...27 Gloves ...9 M Maintenance...
Owners Manual
Page 132
... Spark Plug Inspection ...96 Spark Plug Recommendations...96 Spark Plug Torque Specification...96 Spark Plugs ...96-97 Specifications...116-117 Spring Adjustment, Rear Shock ...85 Starting the Engine ...42 Steering Assembly...85 Steering Lock...26 Storage ...109-114 Storage Tips...112-114 Switches ...20-22 4X4 Switch ...22 Engine Stop Switch ...21 Hazard Warning...22 Headlight Switch ...21 Horn ...22 Light Switch ...21 Main Key Switch ...21 Master Light Switch ...20 Mode/Reverse Override Switch. 20 Turn Signal ...22 P Parking Brake ...24 Parking on an Incline ...55 Periodic Maintenance Chart...
... Spark Plug Inspection ...96 Spark Plug Recommendations...96 Spark Plug Torque Specification...96 Spark Plugs ...96-97 Specifications...116-117 Spring Adjustment, Rear Shock ...85 Starting the Engine ...42 Steering Assembly...85 Steering Lock...26 Storage ...109-114 Storage Tips...112-114 Switches ...20-22 4X4 Switch ...22 Engine Stop Switch ...21 Hazard Warning...22 Headlight Switch ...21 Horn ...22 Light Switch ...21 Main Key Switch ...21 Master Light Switch ...20 Mode/Reverse Override Switch. 20 Turn Signal ...22 P Parking Brake ...24 Parking on an Incline ...55 Periodic Maintenance Chart...