Polaris 500 HHO 2013 User manual

Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
Owner's Manual
for Maintenance and Safety
Sportsman Touring
500 HO

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

The text is printed on 100% recycled
with 40% post-consumer waste (PCW).

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Phone [phone]
Part No. 9923799 Rev 01
Printed in USA
Improper vehicle use can result in SEVERE INJURY or DEATH.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
FOR DRIVER
AND PASSENGER
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
MORE THAN
1 PASSENGER
NEVER USE
WITH DRUGS
OR ALCOHOL
without proper ATV training or instruction
at speeds too fast for your skills or the conditions
on public roads - a collision can occur with another vehicle
with a passenger unless passenger seat is securely in place
THE OPERATOR MUST ALWAYS:
use proper riding techniques to avoid vehicle overturns on hills
and rough terrain and in turns
avoid paved surfaces - pavement may seriously affect handling
and control
reduce speed and use extra caution at all times when carrying a
passenger - dismount passenger when conditions require
make sure passenger reads and understands this label and
passenger safety label
NEVER operate:
*9923799 *
WARNING

1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product
introductions, upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and
recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
•RANGER®utility vehicles
• Victory Motorcycles®
• Low emission vehicles (LEVs)
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.
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 ser-
vice needs during, and after, the warranty period.

2
POLARIS and SPORTSMAN are registered trademarks of POLARIS Industries Inc.
Copyright 2012 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. 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.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
2013 SPORTSMAN Touring 500 HO Owner’s Manual
P/N 9923799

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Emission Control Systems . . . . . . . . . . . . . . . 66
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 120
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 124
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 126
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 135
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4
INTRODUCTION
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.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

5
INTRODUCTION
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. 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 this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a POLARIS ATV. Keep this manual
with the ATV.
• Never operate an ATV without proper instruction. Take a training course.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• Never permit a guest to operate the ATV unless the guest has read this
manual and all product labels and has completed a certified safety training
course.
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration lev-
els of this machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was con-
trolled as indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on
many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
WARNING

6
INTRODUCTION
Vehicle Identification Numbers
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.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
####
Engine Serial Number
Key Number
VIN
(front or rear frame)