. Pantone 426C Sportsman 500 HO Owner's Manual for Maintenance and Safety Read this manual carefully.

1. 2008 Polaris Sportsman 500 Efi Service Manual

It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.

WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800- 342-3764 for assistance. The text is printed on 100% recycled with 40% post-consumer waste (PCW). Pantone 426C NEVER CARRY NEVER USE PASSENGERS WITH DRUGS OR ALCOHOL 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.

9922247 Rev 01 Printed in USA. ®. Victory Motorcycles ® We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced. POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris Industries Inc. Copyright 2009 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 result between the actual vehicle and the information presented in this publi- cation.

Troubleshooting. 113 Polaris Products. 117 Specifications. The following signal words and symbols appear throughout this manual and on your vehicle.

Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place.

An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. You should review this information on a regular basis. If you purchased a used Polaris ATV in the United States, you can enroll in the ATV RiderCourse for a fee. Call ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org. Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. 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. SAFETY Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual.

See the OPERATION section of the owner’s manual for proper operating procedures. Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. 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- eling is performed or where gasoline is stored. SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).

SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use.

SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. Always follow proper procedures for travel- ing down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling down- hill. SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. Always maintain a steady speed when climbing a hill.

If all forward speed is lost:. Keep body weight uphill.

SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain.

SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. Before shifting into reverse gear, always check for obstacles or people behind the ATV.

Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast- flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 55).

SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or the operator fall through the ice. Never operate the ATV on a frozen body of water. Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. If an informational or graphic label becomes illegible or comes off, con- tact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label.

General Warning/Discretionary Warning. Safety Decals and Locations General Warning Discretionary Warning Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control.

Loss of control can result in severe injury or death. Cold tire pressure: Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa). Safety Decals and Locations Rack Warning Clutch Cover Warning WARNING. Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch.

Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death. FEATURES AND CONTROLS Switches Headlight AWD Switch Switch Main Key Switch Mode/Reverse Choke Override Engine Switch Stop Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override button. FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly.

The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights. The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle.

FEATURES AND CONTROLS Brake Lever WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes. FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident.

Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. Parking Brake Locking the Parking Brake 1.

Place the transmission in PARK. Squeeze and release the brake lever two or three times, then squeeze and hold.

Push the parking brake lock forward to engage the lock. Release the brake lever. FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.

Never back down a hill. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.

FEATURES AND CONTROLS 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 start- ing.

Fuel Valve The fuel valve is located under the front storage box cover. OFF: For vehicle storage and when transporting. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop.

When the engine is idling, move the lever to the desired gear. FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch.

When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light Switch in the instrument cluster will be. FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. If this occurs, take the ATV to your Polaris dealer for proper diagno- sis. Gear Indicator - This.

FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. The transmission cannot be in reverse when using this feature.

Odometer Mode The odometer records the miles traveled by the ATV. FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.

FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. Toggle to the service interval screen.

Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference. 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. Enter the diagnostic mode. Toggle to the screen that displays either kilometers (KM) or miles (MP). Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.

No single action on your part is as important as following the proce- dures for a proper break-in. Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Check the oil level on the dipstick. Add oil if neces- sary to maintain the level between the safe and add marks. Safe Operation Practices 1.

Complete the recommended safety training before operating this vehicle. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle. 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 our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles,. OPERATION Starting the Engine 1.

Position the vehicle on a level surface outdoors or in a well-venti- lated area. Place the transmission in PARK. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged. Water in the bottom of the crankcase can lead to engine damage and must be drained.

Water accu- mulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

OPERATION Driving Procedures 1. Wear a helmet and eye protection. Sit upright with both feet on the footrests and both hands on the handlebars. Start the engine and allow it to warm up. Shift the transmission into gear. OPERATION Turning the Vehicle Your ATV 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.

OPERATION 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. Slow down when entering slippery areas.

Driving Uphill Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn.

When- ever traveling uphill, follow these precautions: 1. Drive straight uphill. Avoid steep hills (25° maximum). OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn.

Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Driving Downhill When driving downhill, follow these precautions: 1. Avoid steep hills (25° maximum).

Shift body weight uphill. Drive straight downhill. Excessive speed when traveling downhill can cause loss of control.

Squeeze the brake lever gradually. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of con- trol. OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

Stop and lock the parking brake while keeping body weight uphill. Driving Through Water Your ATV 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. OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. Look ahead and learn to read the terrain.

Be constantly alert for haz- ards such as logs, rocks and low hanging branches. Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always avoid backing downhill. Apply the brakes lightly for stopping.

Avoid turning at sharp angles. OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter 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 cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

ATV warranty. Never install a hitch longer than 4' (10 cm). Never install automotive accessories on your Polaris ATV. Always install Polaris- approved (or equivalent) accessories designed for ATV use. OPERATION Maximum. OPERATION Parking on an Incline Avoid parking on an incline if possible.

If it's unavoidable, follow these precautions: 1. Stop the engine. Place the transmission in PARK. Lock the parking brake.

Always block the rear wheels on the downhill side. CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1c.

Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 129. Improperly performing the procedures marked with a component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services.

Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use. (if equipped) Transmission oil Engine breather filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Hours Calendar Miles (Km). Periodic Maintenance Chart Item Hours Calendar General lubrication Carburetor float bowl Throttle Cable/ ETC Switch Choke cable E Carburetor air intake ducts/flange Drive belt Cooling system Engine oil change Oil filter change Valve clearance Fuel system/filter Radiator (if applicable) Cooling hoses (if applicable) Engine mounts Exhaust muffler/.

Spark arrestor Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 100 H 12 M 1000 (1600) Inspect. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion. Item Engine Oil Polaris Premium 4 Synthetic 0W40 Brake Fluid DOT 4 Only Transmission Oil. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it's 0W- 40.

Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer's recommendations for ambient tem- perature operation. Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the ATV. A rising oil level between checks in cool weather driving can indicate contaminants such as gas or mois- ture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately. 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.

Position the vehicle on a level surface. Start the engine. Allow it to idle for two to three minutes. 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. Using a clean dry cloth, clean the filter sealing surface on the crank- case. Lubricate the o-ring on the new filter with a film of fresh engine oil. 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. 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 relief slit. Periodic Maintenance Chart beginning on page 62. Maintain the oil level at the bottom of the fill plug hole threads.

We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 117 for the part numbers of Polaris products.

Demand Drive Plus Fluid. Use of other fluids may result in improper operation of components. See page 117 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole threads.

Front Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface.

Remove the fill plug. Check the fluid level. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use.

Do not dilute with water. See page 117 for the part numbers of Polaris products. Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been drained for maintenance or repair. 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 and the diaphragm should be replaced. 1/8' to 1/4' (3-6 mm) toe out alignment. Repeat the measurement procedure on the other side of the vehicle. If you discover improper alignment, see your Polaris dealer for ser- vice. Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts.

If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. Wheel Removal 1.

Stop the engine. Place the transmission in PARK.

MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. Lock the parking brake. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.

Install the wheel nuts and finger-tighten them. Air Filter 1. Remove the seat.

Release the air box cover clips, and remove the air box cover. Loosen the clamp and remove the filter. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. Breather Filter/Hose The breather filter is on the hose that runs between the engine and air box. See illustration above.

Remove the left side panel. Remove the hose clamps from the filter and pull the filter out of the hoses. 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 pro- vided in a compartment on the top of the access door.

MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation.

Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers. Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall.

Place the transmission in PARK. MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. Lift the pod slightly while depressing the tabs at the rear of the pod. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly.

Remove the headlamp and install the new headlamp. Reinstall the harness assembly into the headlight assembly.

Refer to the specifications section beginning on page 118 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.

Plug Condition New Spark Plug Previously Installed Spark Plug Spark Plug Inspection Spark plug condition is indicative of engine operation. MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark 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. MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below. Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area.

Remove any combustible materials from the area. Wear eye protection and leather work gloves. Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product.

Always make sure the PVT housing is securely in place during operation. MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases.

This, in turn, increases the amount of pinch applied to the drive belt. MAINTENANCE PVT System When To Use Low Range and High Range Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 MPH (11 km/h) PVT Drying There may be some instances when water is accidently ingested into the PVT system. Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

WARNING Battery electrolyte is poisonous. MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. Remove the battery cover. On conventional batteries, remove the battery vent tube. Disconnect the black (negative) battery cable first.

Disconnect the red (positive) battery cable last. Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 101 before installing the battery. Tip: Power plug leads may need to be bent down so that the battery cover can be installed. Polaris recommends maintaining battery charge by using a Polaris Bat- tery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Battery Charging (Conventional Battery) 1.

Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.

2008 Polaris Sportsman 500 Efi Service Manual

Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action specified on top of battery) None, check at 3 mos. Follow the adjustment procedures exactly, or see your Polaris dealer for service. Remove the upper headlight pod. Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in.

Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. Locate the throttle cable adjuster at the handlebar.

Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. Do not allow these types of products to contact the vehicle.

The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container.

Polishing Tips. Avoid the use of automotive products, some of which can scratch the finish of your vehicle. MAINTENANCE Cleaning and Storage 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. Stabilize the Fuel 1.

Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems. Treat the fuel system with Polaris Carbon Clean. See page 109. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.

Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated mate- rials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation. Transporting the ATV Follow these procedures when transporting the vehicle.

Stop the engine. Place the transmission in PARK.

Lock the parking brake. Secure the fuel cap, oil cap and seat. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Dry out the PVT. Inspect clutch seals for damage if repeated leaking occurs.

See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines.

See your dealer. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing). Replace with fresh recommended fuel Turn the fuel valve on Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Inspect, clean and/or replace spark plugs Recharge the battery to 12.8 VDC See your dealer. Add or change fuel, clean the fuel system Inspect and replace Replace with recommended fuel Replace filter Replace with recommended fuel See your Polaris dealer Solution Replace with lower octane fuel Inspect, clean and/or replace spark plugs Allow engine to warm up before operat.

TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Overuse of choke Water is present in fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel. Chain Lube, Aerosol (6.25 oz./185 ml) 2872348 Chain Lube, Aerosol (16 oz./473 ml) 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 2859044 Polaris Battery Tender Engine Lubricant Coolant Additives / Miscellaneous 565 Thread Sealant Charger. SPECIFICATIONS Gross Vehicle Weight Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Capacity Demand Drive Fluid Capacity Coolant Capacity Front Rack/Storage Box Capacity 90 lbs. (40.8 kg) Rear Rack/Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity. Overall Length.

Clutching Chart Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) Sportsman 500 Automatic PVT (Polaris Variable Transmission) MacPherson strut with 8.2' (21 cm) travel Progressive rate with 9.5' (24 cm) travel Side Lever (H/L/N/R/P) 23.91:1 16.30:1 10.49:1 3.82:1 25x8-12 / 5 psi. Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES 98/37/EC as amended (Machinery Directive). WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.

WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES 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 ATV that. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or com- ponents or products.

THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR- RANTY. HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.

How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. 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. This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc.

Warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S. Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that you use only Pure Polaris parts.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls. MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS. MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS. Accessories.111 Air Filter. 83 All Wheel Drive System.

Periodic Maintenance Chart.62-66 Polaris Product List. 117 Polishing the Vehicle. 107 Pre-Ride Checklist. Safe Operation Practices.43 Safety Decals.21-23 Safety Labels 'No Passenger' Warning.22 Age 16 Warning.