Polaris 2009 Sportsman X2 500 EFI User manual

02

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 engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING

1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
SSnowmobiles
SAll-terrain vehicles (ATVs)
SRANGER utility vehicles
SVictory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!

2
Copyright 2005 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
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2006 Sportsman X2 500 EFI Owner’s Manual P/N 9920361

3
TABLE OF CONTENTS
VEHICLE IDENTIFICATION NUMBERS 5.......
SAFETY 6...................................
CONTROLS 36...............................
FEATURES 43...............................
OPERATION 52..............................
EMISSION CONTROL SYSTEMS 73............
MAINTENANCE 74...........................
ADJUSTMENTS 115..........................
POLARIS PRODUCTS 117....................
TROUBLESHOOTING 118.....................
SPECIFICATIONS 122........................
WARRANTY 124.............................
MAINTENANCE LOG 130.....................
INDEX 132...................................

4

5
VEHICLE IDENTIFICATION NUMBERS
Record your ATV’s identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place.
Your key can be duplicated only by mating a Polaris key blank with
one of your existing keys, so if both keys are lost, the ignition switch
must be replaced.
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
Key Number (3):
2
1
3
31XX

6
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals on the ATV carefully. If any
of the decals depicted in this manual differ from the decals on your
ATV, always read and follow the instructions of the decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
WARNING
SNever operate this vehicle on HILLS steeper than 15 degrees.
To prevent flipover on hilly terrain, when going up or down,
use throttle and brakes gradually.
SNever operate this vehicle in TURF mode on irregular terrain,
including hills and obstacles.
SREVERSE operation can be dangerous even at low speeds.
Steering becomes difficult. To prevent flipover, avoid sudden
braking or sharp turns.
SUse OVERRIDE for reverse speed limiter with caution. To prevent
loss of control, never activate override button with open throttle.
SWhen this vehicle is not in operation or unattended, place shift
in the park position.
7173948
A
B
A

ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
FOR OPERATOR
AND PASSENGER
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
MORE THAN
ONE
PASSENGER
NEVER USE
WITH DRUGS
OR ALCOHOL
B
7
SAFETY
Safety Decals and Locations
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
NEVER operate:
Swithout proper training or instruction
Sat speeds too fast for your skills, your passenger’s skills,
or the conditions
Son public roads -- a collision can occur with another vehicle
Swith more than one passenger -- passengers affect balance
and steering and increase risk of losing control
Swith a passenger under the age of 12
THE OPERATOR MUST ALWAYS:
Suse proper riding techniques to avoid vehicle overturns
on hills and rough terrain and in turns
Savoid paved surfaces -- pavement may seriously affect
handling and control
Sreduce speed and use extra caution at all times when carrying a
passenger -- have passenger dismount when conditions require
Smake sure passenger reads and understands this label and
passenger safety label
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
IF OWNER’S MANUAL IS MISSING, CONTACT
A POLARIS DEALER FOR A REPLACEMENT.
E1997, 2000 7173889

8
SAFETY
Safety Decals and Locations
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, OPERATOR, PASSENGER AND
CARGO IS 1500 LBS. (680 kg)
Reduce speed and allow greater distance for braking when carrying
cargo. Overloading or carrying tall, off-center, or unsecured loads
will increase your risk of losing control. Loads should be centered,
carried as low as possible in box, and firmly secured to the rack. For
stability on rough or hilly terrain, reduce speed and cargo. Do not block
headlight. Be careful if load extends over the side of the rack or box.
Read Owner’s Manual for more detailed loading information.
7173900
ATTENTION
SOperation of this vehicle without the air filter element will
severely damage the engine.
SClean pre-filter element often, more frequent cleaning required
in dusty conditions. Do not operate vehicle without pre-filter.
7172921
C
E
D
F
G
C
D

9
SAFETY
Safety Decals and Locations
WARNING
Operating this vehicle if you are under the
age of 16 increases your chance of severe
injury or death.
NEVER operate this ATV if you are under
age 16.
7172588
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover
may result causing severe injury or death. Tow only from tow hooks or
hitch. Max. combined Front Rack and container Load 90 lbs. (41 kg).
7172569
WARNING
Remove flammable material containers from box before filling.
WARNING
Passengers can be thrown off. This can cause serious injury or death.
Never carry passengers in cargo box.
Max. Box Load - 400 lbs. (181 kg)
E
F
G

NEVER CARRY
A PASSENGER
UNDER AGE 12
NEVER CARRY
MORE THAN ONE
PASSENGER
NEVER RIDE AFTER
USING DRUGS OR
ALCOHOL
H
PASSENGER
UNDER
12
10
SAFETY
Safety Decals and Locations
WARNING
PASSENGER SAFETY
To reduce the risk of SEVERE INJURY or DEATH.
NEVER carry a passenger too small to firmly plant feet
on footrests and securely grasp hand holds.
THE PASSENGER MUST ALWAYS:
Suse an approved helmet and protective gear
Ssecurely grasp hand holds and plant feet firmly
on footrests
Stell operator to slow down or stop if
uncomfortable -- get off and walk if conditions
require
7174028
I
H

I
11
SAFETY
Safety Decals and Locations
WARNING
SMoving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle with
guard removed.
SDo 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.
NO STEP 7172563
ALL WHEEL
DRIVE
SWITCH
Do not push switch to
engage AWD if the rear
wheels are spinning.
This may cause severe
drive shaft and clutch
damage.
See your Owner’s
Manual.
7079780
7172564
Pushing reverse
override button
may cause
sudden increases
in power and
traction if too
much throttle is
applied. Loss of
control or forward
flipover may
result, especially
in AWD. See
Owner’s Manual.
7174159
TRAILER MAX WEIGHT:
1225 LBS. (557 KG) ON LEVEL GROUND
HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55KG)
MANUFACTURED
BY: POLARIS IND. INC.
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT
INTENDED FOR USE ON PUBLIC ROADS.
7171492
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST
PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.
Canadian Certification Decal
WARNING

12
SAFETY
Safety Training
ATV safety training is a top priority for Polaris. When you purchased
your new ATV, your dealer instructed you on the authorized ATV
RiderCoursesm available to you and your eligible family members.
This training is included in the purchase price of your ATV. Polaris
strongly encourages you and your eligible family members who will be
riding the ATV to take the ATV RiderCoursesm.Youwerealso
provided with printed materials that explain safe operating procedures.
You should review this information on a regular basis.
If you purchased a used Polaris ATV, you can take the ATV
RiderCoursesm by calling ATV Enrollment Express at [phone]
or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV
will be charged for this training.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of the ATV in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. Never allow anyone under 12 years
of age to ride as a passenger on this 2-up ATV.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others (including your passenger), and the
protection of our environment. Read and understand your owner’s
manual, which includes valuable information about all aspects of your
vehicle, including safe operating procedures.

13
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires
special protective clothing for comfort and to reduce the chance of
injury.
1. Helmet
Your helmet is the most important piece of
protective gear for safe riding. A helmet
can prevent a severe head injury.
Select an approved helmet that meets or
exceeds your state’s safety standards and
bears either the Department of
Transportation (DOT) label, the
American National Standards Institute
label (ANSI z90.1), or the Snell
Memorial Foundation label.
A passenger’s helmet should have a rigid
chin guard.
2. Eye Protection
Do not depend on sunglasses for
proper eye protection. A pair of goggles
or a helmet face shield offer the best
protection for your eyes. They should be
kept clean and be of shatterproof design
(bearing the markings Z2.1 or VESC 8).
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
4. Boots
The best footwear is a pair of strong over-the-calf boots with heels, like
moto-cross boots.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide
the best protection.
1
2
3
4
5

14
SAFETY
Rider Safety
WARNING
Failure to follow the warnings contained in this manual can result
in serious 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. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.
The following signal words and symbols appear in this manual and on
your vehicle. Your safety is involved when these words and symbols are
used. Become familiar with their meanings before reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
Acaution indicates a situation that may result in damage to the
vehicle.
NOTE:
Anote will alert you to important information or instructions.

15
SAFETY
Rider Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
SRead this manual and all labels carefully, and follow the operating
procedures described.
SNever operate an ATV without proper instruction. Take a training
course. Purchasers of a new Polaris ATV and their eligible family
members are entitled to take the ATV RiderCoursesm. Contact ATV
Enrollment Express at [phone] or visit www.atvsafety.org for
information on enrollment in the ATV RiderCoursesm.
SNever allow anyone under 16 years of age to operate this ATV.
SNever allow anyone under 12 years of age to ride as a passenger on
this 2-up ATV. Make sure any passenger is tall enough to comfort-
ably and safely reach the handgrips and footrests.
SNever secure a passenger to the vehicle or to the operator with a belt,
rope or similar device.
SNever carry more than one passenger on this 2-up ATV.
SAlways make sure the passenger seat lock-out is functioning proper-
ly before carrying a passenger.
SNever permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safe-
ty training course.
SAlways keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation. A passenger should always be
seated in the passenger seat with both feet on the footrests and both
hands on the passenger grab handles at all times. The passenger
should never hold on to the operator.
SAlways avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
SNever operate an ATV on a public street, road or highway, including
a dirt or gravel road.
SNever ride an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants. A pas-
senger’s helmet should have a rigid chin guard.
SNever consume alcohol or drugs before or while riding an ATV.

16
SAFETY
Rider Safety
SNever operate at excessive speeds. Travel at speeds appropriate for
your skills, your passenger’s skills, and operating conditions.
SNever attempt wheelies, jumps or other stunts.
SAlways inspect your ATV before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
SAlways travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
SNever operate on excessively rough, slippery, or loose terrain.
SAlways follow proper turning procedures as described in this manu-
al. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
SAlways have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
SAlways be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skid-
ding or sliding out of control.
SNever operate on hills too steep for the ATV or for your abilities.
SNever operate this ATV in TURF mode while operating on a hill or
other irregular terrain. See page 43.
SAlways follow proper procedures for climbing hills. Check the ter-
rain carefully before ascending a hill. Never climb hills with exces-
sively slippery or loose surfaces. Shift body weight uphill. Never
open the throttle suddenly or make sudden gear changes. Never go
over the top of a hill at high speed. Switch the AWD switch out of
TURF mode and into AWD mode when ascending a hill.
SAlways follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill.
Shift body weight uphill. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when pos-
sible.
SAlways follow proper procedures for crossing the side of a hill. Do
not cross a hillside with a passenger on board. Avoid hills with ex-
cessively slippery or loose surfaces. Shift body weight uphill. Nev-
er attempt to turn the ATV around on any hill until you’ve mastered
(on level ground) the turning technique outlined in this manual.
Avoid crossing the side of a steep hill when possible.

17
SAFETY
Rider Safety
SAlways use proper procedures if you stall or roll backwards while
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special
procedure for braking described in this manual. Always dismount
on the uphill side, or to either side if the ATV is pointed straight
uphill. Turn the ATV around and remount following the procedure
described in this manual.
SAlways check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees.
Always follow proper procedures when operating over obstacles as
described in this manual.
SAvoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sud-
den movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
SWet brakes may have reduced stopping ability. Test the brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
SAlways check for obstacles or people behind the ATV before operat-
ing in reverse. Be aware that a passenger can obstruct your view.
When it’s safe to proceed in reverse, move slowly and avoid turning
at sharp angles.
SAlways use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
SNever modify an ATV through improper installation or use of acces-
sories.
SNever exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the
Consumer Product Safety Commission at 1-800-638-2772,
or visit www.cpsc.gov, visit www.atvsafety.org, or call
Polaris at 1-800-342-3764.