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!

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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

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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
+

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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