Polaris Sportsman 500 H.O. User manual

Pantone 425 C
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 or the conditions.
Son public roads - a collision can occur with another
vehicle.
Swith a passenger - passengers affect balance and
steering and increase risk of losing control.
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.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
For your nearest Polaris dealer,
visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
U.S.A.
Part No. 9922553 Rev 02
Printed in U.S.A.

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
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at
www.polarisindustries.com.

2
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries 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. 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.
2010 Sportsman 500 HO International Owner’s Manual
P/N 9922553

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 34
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Emission Control Systems . . . . . . . . . . . . . . . 56
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 114
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 116
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 117
Declaration of Conformity . . . . . . . . . . . . . . . 121
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 125
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may 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 follow the warnings in this manual can result in serious injury or death.
This Polaris vehicle is not a toy and can be hazardous to operate. A collision or
rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
Read and understand your owner's manual and all warnings before operating
this Polaris vehicle.
Safety Training
When you purchased your new Polaris vehicle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this informa-
tion on a regular basis.
If you purchased a used Polaris vehicle from a party other than a Polaris
dealer, please request free safety training from any authorized Polaris
dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a
trailer with this vehicle on public roads is prohibited.
Equipment Modifications
The warranty on your Polaris vehicle may be terminated if any equip-
ment has been added, or if any modifications have been made, that
increase speed or power. The addition of certain accessories, including
(but not limited to) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only Polaris-approved accessories. Know
their function and effect on the vehicle.
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: ___________________________________________________________
####
VIN Engine Serial Number
Key Number

7
SAFETY
Operator Safety
Serious injury or death can result if you do not follow the instructions and
procedures listed here and throughout this manual.
Read and understand all warnings,
cautions and operating procedures in
this manual and on the safety labels
before operating the vehicle.
Never operate this vehicle without
proper instruction. Take a training
course. Beginners should receive
training from a certified instructor.
Contact an authorized Polaris dealer
or visit the Polaris web site at www.polarisindustries.com.
Never permit others to operate the vehicle unless they have read and
understand this manual and all product labels, and have completed a certified
safety training course.
Never allow anyone under 16 years of
age to operate this vehicle.
Never carry a passenger. The purpose
of the long seat is to allow the operator
to shift position.
WARNING

8
SAFETY
Operator Safety
Always wear an approved helmet that
fits properly. Wear eye protection
(goggles or face shield), gloves,
boots, long sleeves and long pants.
Never consume alcohol or drugs
before or while operating this vehicle.
Never operate at excessive speeds.
Travel and turn at speeds appropriate
for the terrain, visibility, operating
conditions and your experience.
Never attempt jumps or other stunts.

9
SAFETY
Operator Safety
Always inspect your Polaris vehicle
before each use to verify that it's in
safe operating condition. Follow the
inspection and maintenance
procedures outlined in this manual.
See page 53.
Keep both hands on the handlebars.
Keep your feet on the footrests.
Always travel slowly when operating
on unfamiliar terrain. Use extra
caution.
Use caution when operating on rough,
slippery or loose terrain.
Always follow the procedures outlined
in this manual for turning. See page
19.
Never turn sharply at excessive
speeds, which can lead to vehicle
overturn.

10
SAFETY
Operator Safety
If the vehicle has been involved in an
accident, always have an authorized
Polaris dealer inspect the entire
vehicle for possible damage, including
(but not limited to) brake, throttle and
steering systems.
Never operate on hills too steep for
the vehicle or for your abilities.
Practice on smaller hills before
attempting larger hills. Avoid climbing
hills steeper than 25°.
Always follow the procedures outlined
in this manual for climbing hills. See
page 22.
Always follow the procedures outlined
in this manual for driving downhill and
for braking on hills. See page 25.
Always follow the procedures outlined
in this manual for crossing the side of
a hill. See page 24.
Never attempt to turn the vehicle
around on any hill until you've
mastered (on level ground) the turning
technique outlined in this manual.

11
SAFETY
Operator Safety
Always follow the procedures outlined
in this manual for braking if you stall or
roll backwards while climbing a hill.
Never back down a hill. See page 26.
Always follow the procedures outlined
in this manual for operating over
obstacles. See page 21.
Always follow the procedures outlined
in this manual for operating on
slippery or loose surfaces. Use extra
caution. Always avoid skidding or
sliding. See page 20.
Always follow the procedures outlined
in this manual for driving through
water. Never drive through deep or
fast-flowing water. See page 28.

12
SAFETY
Operator Safety
Always follow the procedures outlined
in this manual for driving in reverse.
See page 31.
Always use the size and type of tires
specified for your vehicle. Maintain the
proper tire pressure.
Never modify this Polaris vehicle
through improper installation or use of
accessories.
Never exceed the stated load capacity
for your vehicle. 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.

13
SAFETY
Operator Safety
Never operate the vehicle on a frozen
body of water.
Operating on paved surfaces may
affect the handling and control of the
vehicle and could result in loss of
control. Avoid sudden turns or swift
movement of the handlebars.
Always remove the ignition key when
the vehicle is not in use to prevent
unauthorized use or accidental
starting.
Always unlock the steering before
starting the engine. See page 40.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about safety, contact an
authorized Polaris dealer or visit the Polaris web site at
www.polarisindustries.com.

14
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If a label
becomes illegible or comes off, contact 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.
The following pages repeat the information found on each label.
General Alert
(Multi-Lingual)
Before you operate this
vehicle, read the owner’s
manual.
Hill Operation Alert
• Never operate this vehicle on HILLS
steeper than 25 degrees 25°.
• To prevent flip-over on hilly terrain,
when going up or down, use throttle
and brakes gradually.
+
General
Alert
+
Hill
Operation
Alert
+
Age 16
Alert

15
SAFETY
Safety Labels and Locations
“No Passenger” Warning
WARNING - NEVER ride as a passenger. Passengers can cause a loss of
control, resulting in SEVERE INJURY or DEATH.
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING
MACHINE, DRIVER AND CARGO IS 1200 LBS. (546 kg). Read Owner's
Manual for more detailed loading information.
Clutch Cover Alert
NO STEP
Rack Warning, Front and Rear
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)
Reverse Override Alert
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.
+
“No Passenger”
Warning
+
+
Rack
Warning Rack
Warning
Tire Pressure/
Load Alert
+
+
Clutch
Cover Alert

16
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Always wear a helmet that meets or exceeds established safety stan-
dards.
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

17
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.

18
SAFETY
Driving Safely
Driving Procedures
1. Sit upright. Keep your feet on the footrests. Keep both hands on the
handlebars.
2. Apply the brakes.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear.
5. Check your surroundings and determine your path of travel.
6. Release the brakes.
7. Slowly squeeze the throttle lever toward the handlebar to begin
driving.
8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.