Polaris Sportsman 500 EFI User manual

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.
• Snowmobiles
• All-terrain vehicles (ATVs)
•RANGER utility vehicles
• 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.
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.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!

2
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
Copyright 2007 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.
Printed in U.S.A.
2008 Sportsman 500 Touring/Sportsman 800 Touring Owner’s Manual
P/N 9920630

3
TABLE OF CONTENTS
Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls . . . . . . . . . . . . . . . . . . . 36
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Emission Control Systems . . . . . . . . . . . . . . . 78
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 133
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 137
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 138
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 148
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

4

5
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 protec-
tion of our environment. Read and understand your owner's manual,
which includes valuable information about all aspects of your vehicle,
including safe operating procedures.
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: ___________________________________________________________
####
VIN Engine Serial Number
Key Number
500
800

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.
Discretionary Warning
WARNING
• Never operate this ATV on HILLS
steeper than 15 degrees 15°.To
prevent flip-over on hilly terrain, when
going up or down, use throttle and
brakes gradually.
• Never operate this vehicle in
mode on irregular terrain, including
hills and obstacles.
• REVERSE operation can be
dangerous even at low speeds.
Steering becomes difficult. To prevent
flipover, avoid sudden braking or
sharp turns.
• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of
control, never activate override button with open throttle.
• When this vehicle is not in operation, or unattended, place shift in the park
position.
7175108
Age 16 Warning
WARNING
Operating this ATV 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
+
Discretionary Warning
Age 16 Warning
+

7
SAFETY
Safety Decals and Locations
General Warning
WARNING
Improper ATV use can result in SEVERE
INJURY or DEATH
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
NEVER operate:
• without proper training or instruction
• at speeds too fast for your skills, your passenger’s skills, or the conditions
• on public roads - a collision can occur with another vehicle
• with more than one passenger - passengers affect balance and steering and
increase risk of losing control
• with a passenger under the age of 12
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 -
have passenger dismount when conditions require
• make 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.
7173889
+
General
Warning

8
SAFETY
Safety Decals and Locations
Passenger Safety Warning
WARNING
PASSENGER SAFETY
To reduce the risk of SEVERE INJURY or DEATH
NEVER CARRY A PASSENGER UNDER AGE 12
NEVER CARRY MORE THAN ONE
PASSENGER
NEVER RIDE AFTER USING DRUGS OR
ALCOHOL
NEVER carry a passenger too small to firmly plant
feet on footrests and securely grasp hand holds.
THE PASSENGER MUST ALWAYS:
• use an approved helmet and protective gear
• securely grasp hand holds and plant feet firmly on footrests
• tell operator to slow down or stop if uncomfortable - get off and walk if
conditions require
7174028
Tire Pressure/Load Warning
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 600 LBS.
(272 kg) INCLUDES WEIGHT OF
OPERATOR, PASSENGER, CARGO AND
ACCESSORIES.
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, 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.
Read Owner's Manual for more detailed loading information.
7175089
+
Passenger Safety
Warning
+
Tire Pressure/Load
Warning

9
SAFETY
Safety Decals and Locations
Rack Warning
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.
Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
7172572
Clutch Cover Warning
WARNING
NO STEP
• 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.
7172563
Reverse Override Warning
WARNING
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 4X4 (AWD). See Owner's Manual.
7175106
+
Clutch Cover
Warning
+
+
Rack
Warning Rack
Warning

10
SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.
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.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31

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SAFETY
Safe Riding Gear
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. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
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.

12
SAFETY
Rider Safety
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.
WARNING
Failure to follow the warnings 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 and understand your owner's manual and all warnings before operating
a Polaris ATV.

13
SAFETY
Rider 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. You were also 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 this vehicle 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.

14
SAFETY
Rider Safety
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, on your vehicle or in this manual, alerts you to the
potential for 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
injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE
A note will alert you to important information or instructions.

15
SAFETY
Rider Safety
• Read this manual and all labels carefully, and follow the operating
procedures described.
• Never 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.
• Never allow anyone under 16 years of age to operate this ATV.
• Never 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 comfortably
and safely reach the handgrips and footrests.
• Never secure a passenger to the vehicle or to the operator with a belt,
rope or similar device.
• Never carry more than one passenger on this 2-up ATV.
• Always make sure the passenger seat is installed and securely latched
before operating with a passenger.
• 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.
• Always 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.
• Always avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
• Never operate an ATV on a public street, road or highway, including a
dirt or gravel road.
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.

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SAFETY
Rider Safety
• Never operate 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 passenger's
helmet should have a rigid chin guard.
• Never consume alcohol or drugs before or while operating an ATV.
• Never operate at excessive speeds. Travel at speeds appropriate for
your skills, your passenger's skills, and operating conditions.
• Never attempt jumps or other stunts.
• Always 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.
• Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
• Never operate on excessively rough, slippery, or loose terrain.
• Always follow proper turning procedures as described in this manual.
Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
• Always have the ATV inspected by an authorized Polaris dealer if it's
been involved in an accident.
• Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
• Never operate with the differential unlocked ()while operating on
a hill or other irregular terrain. See pages 37 and 47.
• Always follow proper procedures for climbing hills. Check the terrain
carefully before ascending a hill. Never climb hills with excessively
slippery or loose surfaces. Shift your weight uphill. Never open the
throttle suddenly or make sudden gear changes. Never go over the top
of a hill at high speed. Always move the 4X4 switch to ADC 4X4
before ascending or descending a hill.

17
SAFETY
Rider Safety
• Always follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill. Shift
your 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. Drive straight downhill.
• Always follow proper procedures for crossing the side of a hill. Do
not cross a hillside with a passenger on board. Avoid hills with exces-
sively slippery or loose surfaces. Shift your weight uphill. Never
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.
• Always 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 pro-
cedure 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.
• Always 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.
• Always 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.
• Avoid 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.
• Wet 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.

18
SAFETY
Rider Safety
• Always 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.
• Always use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
• Never modify an ATV through improper installation or use of acces-
sories.
• Never 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.

19
SAFETY
Rider Safety
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not install
on a Polaris ATV any equipment that may increase the speed or power
of the vehicle, or make any other modifications to the vehicle for these
purposes. Any modifications to the original equipment of the vehicle
create a substantial safety hazard and increase the risk of bodily injury.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to the
vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers, or large racks, may change the handling
characteristics of the vehicle. Use only Polaris-approved accessories,
and familiarize yourself with their function and effect on the vehicle.

20
SAFETY
Rider Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the
operator does not know how to operate the ATV
properly in different situations and on different
types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should
complete the ATV RiderCoursesm offered by
Polaris through the SVIA. They should then
regularly practice the skills learned in the course and the operating
techniques described in the Owner's Manual.
For more information about the ATV RiderCoursesm contact ATV Enrollment
Express at [phone] or visit www.atvsafety.org.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN HAPPEN
Severe injury and/or death could occur if a child under the minimum age
recommendation operates this ATV or rides as a passenger.
Even though a child may be within the recommended age group for operating
some ATVs, he/she may not have the skills, abilities, or judgment needed to
operate or ride on this ATV safely and could be susceptible to accident or
injury.
HOW TO AVOID THE HAZARD
No one under the age of 16 should operate a Polaris ATV. Never allow
anyone under 12 years of age to ride as a passenger on this 2-up ATV.