Owners Manual
Page 4
... whole or in U.S.A. 2013 Sportsman 500 Tractor Owner's Manual P/N 9923938 2 Printed in part, is based on the latest product information at the time of POLARIS Industries Inc. No liability can be accepted for reference use only. Any reprinting or reuse of the depictions and/or procedures contained within this publication. POLARIS, THE WAY OUT and SPORTSMAN are intended for omissions...
... whole or in U.S.A. 2013 Sportsman 500 Tractor Owner's Manual P/N 9923938 2 Printed in part, is based on the latest product information at the time of POLARIS Industries Inc. No liability can be accepted for reference use only. Any reprinting or reuse of the depictions and/or procedures contained within this publication. POLARIS, THE WAY OUT and SPORTSMAN are intended for omissions...
Owners Manual
Page 30
... for towing a trailer. Rear Hitch Specifications Material Fasteners Weld Length and Positions Maximum Vertical Load Maximum Towable Mass Approval # 1021 M Steel 1008K Steel (Main Pin and Receiver Pin) 3 mm fillet, both sides, all around 75 kg (on coupling point) 750 kg e11*89/173*2006/26*2073*xx 28 Do not use the front hitch for hitch weight capacities. FEATURES AND CONTROLS Hitches...
... for towing a trailer. Rear Hitch Specifications Material Fasteners Weld Length and Positions Maximum Vertical Load Maximum Towable Mass Approval # 1021 M Steel 1008K Steel (Main Pin and Receiver Pin) 3 mm fillet, both sides, all around 75 kg (on coupling point) 750 kg e11*89/173*2006/26*2073*xx 28 Do not use the front hitch for hitch weight capacities. FEATURES AND CONTROLS Hitches...
Owners Manual
Page 32
ADC 4X4 When the switch is moving can cause transmission damage. NOTICE: Shifting gears with the engine speed above idle or while the vehicle is on the right side of the vehicle. All Wheel Drive (4X4) System The All Wheel Drive system is locked when it's in PARK. The transmission is controlled by the 4X4 switch. Belt Life To extend belt life, use LOW forward gear when pulling a heavy load at less than...
ADC 4X4 When the switch is moving can cause transmission damage. NOTICE: Shifting gears with the engine speed above idle or while the vehicle is on the right side of the vehicle. All Wheel Drive (4X4) System The All Wheel Drive system is locked when it's in PARK. The transmission is controlled by the 4X4 switch. Belt Life To extend belt life, use LOW forward gear when pulling a heavy load at less than...
Owners Manual
Page 33
... in two-wheel drive at rest. 31 FEATURES AND CONTROLS All Wheel Drive (4X4) System 4X4 When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the rear wheels regain traction...
... in two-wheel drive at rest. 31 FEATURES AND CONTROLS All Wheel Drive (4X4) System 4X4 When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the rear wheels regain traction...
Owners Manual
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... wheels when the vehicle descends a hill or incline. 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...
... wheels when the vehicle descends a hill or incline. 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...
Owners Manual
Page 36
... the instrument cluster may have shut off to your POLARIS dealer for 2.5 seconds at start-up for proper diagnosis. 1. Gear Indicator - Engine Hour Display Indicator 4. Odometer/Tachometer/Tripmeter/ Hour Meter 6. Check Engine Warning Indicator - Serious engine damage could result. 8. FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the fuel tank. This 8 indicator illuminates when the 4X4 switch is activated. Refuel immediately. 7. Service...
... the instrument cluster may have shut off to your POLARIS dealer for 2.5 seconds at start-up for proper diagnosis. 1. Gear Indicator - Engine Hour Display Indicator 4. Odometer/Tachometer/Tripmeter/ Hour Meter 6. Check Engine Warning Indicator - Serious engine damage could result. 8. FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the fuel tank. This 8 indicator illuminates when the 4X4 switch is activated. Refuel immediately. 7. Service...
Owners Manual
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... the recommended fuel. No single action on the daily pre-ride inspection checklist. Vary the throttle positions. PVT Break-in (Clutches/Belt) Break in the clutches and belt by operating at full throttle or high speeds for extended periods during the first three hours of your Tractor more efficient performance and longer life for a proper breakin. Pull only light loads. Drive slowly. Do...
... the recommended fuel. No single action on the daily pre-ride inspection checklist. Vary the throttle positions. PVT Break-in (Clutches/Belt) Break in the clutches and belt by operating at full throttle or high speeds for extended periods during the first three hours of your Tractor more efficient performance and longer life for a proper breakin. Pull only light loads. Drive slowly. Do...
Owners Manual
Page 61
... high on the vehicle warning labels. • NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the operator, accessories, loads in the back. Secure off -centered loads that cannot be centered, securely fasten the load and operate with loads that require backing downhill. • When operating over the rack sides. See specifications beginning on public roads is prohibited. • TOWING SPEED should never exceed...
... high on the vehicle warning labels. • NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the operator, accessories, loads in the back. Secure off -centered loads that cannot be centered, securely fasten the load and operate with loads that require backing downhill. • When operating over the rack sides. See specifications beginning on public roads is prohibited. • TOWING SPEED should never exceed...
Owners Manual
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... 63-64. Perform all services at whichever maintenance interval is reached first. clean often; Hours Calendar Steering Front suspension Rear suspension Tires Brake fluid level Brake lever Foot brake Brake system Passenger seat lock-out Wheels/fasteners Frame fasteners Ź Engine oil level Winch Ź Air filter, pre-filter Ź Air box sediment tube Coolant Ź ADC fluid Headlight/taillight/ work light Kilometers Remarks 70 Inspect; See Pre-Ride Checklist on page 43. MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Ź...
... 63-64. Perform all services at whichever maintenance interval is reached first. clean often; Hours Calendar Steering Front suspension Rear suspension Tires Brake fluid level Brake lever Foot brake Brake system Passenger seat lock-out Wheels/fasteners Frame fasteners Ź Engine oil level Winch Ź Air filter, pre-filter Ź Air box sediment tube Coolant Ź ADC fluid Headlight/taillight/ work light Kilometers Remarks 70 Inspect; See Pre-Ride Checklist on page 43. MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Ź...
Owners Manual
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... 50 6M 6M 6M 800 800 1600 Ź Engine oil change Ź Oil filter change at one month Change fluid every 25 hours if ADC is subjected to extreme use ) Ź Demand drive fluid Ź Rear gearcase oil (if equipped) Ź Transmission oil Ź Engine breather filter (if equipped) Ź General lubrication Shift linkage D Steering Ź Front suspension Ź Rear suspension D Throttle cable/ throttle release switch Throttle body intake duct Drive belt Cooling system 10 20 25 25 Kilometers Inspect; Break...
... 50 6M 6M 6M 800 800 1600 Ź Engine oil change Ź Oil filter change at one month Change fluid every 25 hours if ADC is subjected to extreme use ) Ź Demand drive fluid Ź Rear gearcase oil (if equipped) Ź Transmission oil Ź Engine breather filter (if equipped) Ź General lubrication Shift linkage D Steering Ź Front suspension Ź Rear suspension D Throttle cable/ throttle release switch Throttle body intake duct Drive belt Cooling system 10 20 25 25 Kilometers Inspect; Break...
Owners Manual
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clean; adjust when parts are replaced Adjust as needed Remarks Ź Radiator Ź Cooling hoses Ź Engine mounts Exhaust muffler/ pipe D Spark plug Ź Wiring 100 100 100 100 100 100 12 M 12 M 12 M 12 M 12 M 12 M 1600 1600 1600 1600 1600 1600 D Clutches (drive and driven) D Front wheel bearings D Brake fluid D ADC fluid Ź Fuel filter D Spark arrester D Toe adjustment Headlight aim 100 100 200 200 200 300 12 M 12 M 24 M 24...
clean; adjust when parts are replaced Adjust as needed Remarks Ź Radiator Ź Cooling hoses Ź Engine mounts Exhaust muffler/ pipe D Spark plug Ź Wiring 100 100 100 100 100 100 12 M 12 M 12 M 12 M 12 M 12 M 1600 1600 1600 1600 1600 1600 D Clutches (drive and driven) D Front wheel bearings D Brake fluid D ADC fluid Ź Fuel filter D Spark arrester D Toe adjustment Headlight aim 100 100 200 200 200 300 12 M 12 M 24 M 24...
Owners Manual
Page 99
Position the vehicle on page 96. 97 See torque chart on a level surface. 2. Remove the wheel. 7. 8. 9. 10. Lower the vehicle to raise the wheel slightly off the ground. 5. Place a suitable stand under the footrest frame to the ground. Place the wheel on the hub. Remove the wheel nuts. 6. Loosen the wheel nuts slightly. 4. Place the transmission in PARK. 3. Install the wheel nuts finger tight. MAINTENANCE Tires Wheel Removal/Installation 1. Torque the wheel nuts to specification.
Position the vehicle on page 96. 97 See torque chart on a level surface. 2. Remove the wheel. 7. 8. 9. 10. Lower the vehicle to raise the wheel slightly off the ground. 5. Place a suitable stand under the footrest frame to the ground. Place the wheel on the hub. Remove the wheel nuts. 6. Loosen the wheel nuts slightly. 4. Place the transmission in PARK. 3. Install the wheel nuts finger tight. MAINTENANCE Tires Wheel Removal/Installation 1. Torque the wheel nuts to specification.
Owners Manual
Page 102
Place the transmission in PARK. 3. Measure the distance from a wall. 2. Start the engine.Turn the headlight switch to the left or right. 100 Include rider weight on the wall at the same height. Observe the headlight aim on a level surface. Tighten or loosen the lower headlight screws ...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 seat when measuring. 7.6 m X X 5 cm 4. Position the vehicle on the wall. MAINTENANCE Lights High Beam Adjustment The headlight beam can be 5 cm ...
Place the transmission in PARK. 3. Measure the distance from a wall. 2. Start the engine.Turn the headlight switch to the left or right. 100 Include rider weight on the wall at the same height. Observe the headlight aim on a level surface. Tighten or loosen the lower headlight screws ...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 seat when measuring. 7.6 m X X 5 cm 4. Position the vehicle on the wall. MAINTENANCE Lights High Beam Adjustment The headlight beam can be 5 cm ...
Owners Manual
Page 103
... not service the headlamps until they've cooled. Reach under the front bumper area to reassemble components. Headlight Lamp: Disconnect the harness connector. MAINTENANCE Lights Poor lighting can cause serious burns to the lamp socket or terminals. 6. Wash the headlights and taillights frequently. Hot components can result in PARK. 2. Pull the lamp straight out to release the lamp assembly. 5. Remove the rubber cover...
... not service the headlamps until they've cooled. Reach under the front bumper area to reassemble components. Headlight Lamp: Disconnect the harness connector. MAINTENANCE Lights Poor lighting can cause serious burns to the lamp socket or terminals. 6. Wash the headlights and taillights frequently. Hot components can result in PARK. 2. Pull the lamp straight out to release the lamp assembly. 5. Remove the rubber cover...
Owners Manual
Page 123
... spark plug cap. See page 120. 2. Oil will be completely drained of fresh oil. 6. Turn the engine over several times using electric start. Torque to the inside of engine oil into the plug holes. 3. Apply dielectric grease to specification. 4. Treat the fuel system with a protective film of gasoline. 121 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. If POLARIS fuel system additive is not used, the fuel tank, fuel...
... spark plug cap. See page 120. 2. Oil will be completely drained of fresh oil. 6. Turn the engine over several times using electric start. Torque to the inside of engine oil into the plug holes. 3. Apply dielectric grease to specification. 4. Treat the fuel system with a protective film of gasoline. 121 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. If POLARIS fuel system additive is not used, the fuel tank, fuel...
Owners Manual
Page 126
... cm) unloaded Fuel Capacity 4.12 gal. (15.6 l) Engine Oil Capacity 2 qts. (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 Automatic PVT (POLARIS Variable Transmission) Driving System Type...
... cm) unloaded Fuel Capacity 4.12 gal. (15.6 l) Engine Oil Capacity 2 qts. (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 Automatic PVT (POLARIS Variable Transmission) Driving System Type...
Owners Manual
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SPECIFICATIONS Sportsman 500 Tractor Front Suspension Rear Suspension 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 Winch Headlight Work Lights Parking Lights Taillights Brake Light Instrument Cluster MacPherson strut with 8.2" (21 cm) travel Progressive rate with 9.5" (24 cm) travel 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 Rear-...
SPECIFICATIONS Sportsman 500 Tractor Front Suspension Rear Suspension 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 Winch Headlight Work Lights Parking Lights Taillights Brake Light Instrument Cluster MacPherson strut with 8.2" (21 cm) travel Progressive rate with 9.5" (24 cm) travel 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 Rear-...
Owners Manual
Page 135
however, you may also have other warranty terms will contact the appropriate personnel at POLARIS. If any POLARIS Servicing Dealer to perform warranty service. Please work with your vehicle requires warranty service, you may use your original selling dealer; WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your dealer to resolve any warranty issues. Should your copy of state or federal law, all other rights which vary from...
however, you may also have other warranty terms will contact the appropriate personnel at POLARIS. If any POLARIS Servicing Dealer to perform warranty service. Please work with your vehicle requires warranty service, you may use your original selling dealer; WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your dealer to resolve any warranty issues. Should your copy of state or federal law, all other rights which vary from...
Owners Manual
Page 140
... Spring Adjustment, Rear Shock ...93 Starting the Engine ...44 Steering Assembly...93 Steering Lock...27 Storage ...117-122 Storage Tips...120-122 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 Momentary High Beam Switch . 20 Turn Signal ...22 Winch Switch ...20 Work Light ...22 N Noise Emission Control System ...68 O Oil Engine ...74-79 Transmission ...80-81 Oil Change Engine ...76-79 Transmission ...81 Oil...
... Spring Adjustment, Rear Shock ...93 Starting the Engine ...44 Steering Assembly...93 Steering Lock...27 Storage ...117-122 Storage Tips...120-122 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 Momentary High Beam Switch . 20 Turn Signal ...22 Winch Switch ...20 Work Light ...22 N Noise Emission Control System ...68 O Oil Engine ...74-79 Transmission ...80-81 Oil Change Engine ...76-79 Transmission ...81 Oil...
Owners Manual
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... Throttle Cable Freeplay ...95 Throttle Lever ...23 Throttle Release Switch ...23 Tire Tread Depth...96 Tires ...96-97 Wheel Installation ...97 Wheel Nut Torque ...96 Wheel Removal...97 Toe Alignment ...92 Towing a Disabled Vehicle...123 Towing Capacities ...60 Towing Loads ...60-61 Training, Safety ...7 Transmission ...30 Transmission Oil...80-81 Transporting the Vehicle ...123 Turn Signal Switch ...22 Turning Around on a Hill ...52-53 Turning the Vehicle ...47 V Vehicle Identification Numbers ...6 Vehicle Immersion ...106-107 VIN ...6 W Warning Symbols ...4 Washing the Vehicle...
... Throttle Cable Freeplay ...95 Throttle Lever ...23 Throttle Release Switch ...23 Tire Tread Depth...96 Tires ...96-97 Wheel Installation ...97 Wheel Nut Torque ...96 Wheel Removal...97 Toe Alignment ...92 Towing a Disabled Vehicle...123 Towing Capacities ...60 Towing Loads ...60-61 Training, Safety ...7 Transmission ...30 Transmission Oil...80-81 Transporting the Vehicle ...123 Turn Signal Switch ...22 Turning Around on a Hill ...52-53 Turning the Vehicle ...47 V Vehicle Identification Numbers ...6 Vehicle Immersion ...106-107 VIN ...6 W Warning Symbols ...4 Washing the Vehicle...