Polaris Sportsman 9921837 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)
• Quadricycles/Tractors
•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 2008 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.
2009 Sportsman 500 EFI Tractor Owner’s Manual
P/N 9921837

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Emission Control Systems . . . . . . . . . . . . . . . 60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 116
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 118
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 119
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 126
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.
A Polaris Tractor 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 this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a Polaris Tractor.
• Never operate this vehicle without proper instruction. Take a training course.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Tractor/
trailer combination on public roads is prohibited. See your Polaris dealer
about configuring the vehicle to be certified to tow a trailer on-road.
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
Safety Training
When you purchased your new Tractor, your dealer offered a hands-on
safety training course. You were also provided with printed materials
that explain safe operating procedures. Review this information on a
regular basis.
If you purchased a used Polaris Tractor from a party other than a Polaris
dealer, please request free safety training from any authorized Polaris
dealer.
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment. Read
and understand your owner's manual, which includes valuable informa-
tion about all aspects of your vehicle, including safe operating proce-
dures.
Ride responsibly. Know all laws and regulations concerning the opera-
tion of this vehicle in your area.
Equipment Modifications
The warranty on your Polaris Tractor 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.

8
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

9
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.

10
SAFETY
Rider 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 Tractor.
Never operate a Tractor without proper instruction.
Take a training course. Beginners should receive
training from a certified instructor. Contact an
authorized Polaris Tractor dealer or visit the Polaris
web site at www.polarisindustries.com.
Never permit others to operate the Tractor 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.
Gasoline is highly flammable and explosive under certain conditions.
• Use extreme caution whenever handling gasoline.
• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.
• Never fill a fuel container while it's on the vehicle. Static electricity between
the rack and container could cause a spark.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness resulting in severe injury or death. Never run an engine in an
enclosed area.
WARNING
<
1
6
1
6
1
6

11
SAFETY
Rider Safety
Never carry a passenger on this vehicle.
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 a Tractor.
Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.

12
SAFETY
Rider Safety
Always inspect your Tractor before each
use to verify that it's in safe operating
condition. Follow the inspection and
maintenance procedures outlined in this
manual. See page 41.
Keep both hands on the handlebars. Keep
both feet on the footrests.
Always travel slowly when operating on
unfamiliar terrain. Use extra caution.
Always follow the procedures outlined in
this manual for turning. See page 45.
Never turn sharply at excessive speeds,
which can lead to vehicle overturn.
If a Tractor 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.

13
SAFETY
Rider Safety
Never attempt jumps or other stunts.
Always follow the procedures outlined in this
manual for driving on hills. See page 46.
Never operate on hills too steep for the
Tractor or for your abilities. Practice on
smaller hills before attempting larger hills.
Avoid climbing hills steeper than 25°.
Always move the 4X4 switch to ADC 4X4
before ascending or descending a hill.
Always follow the procedures outlined in this
manual for driving downhill and for braking
on hills. See page 49.
Always follow the procedures outlined in this
manual for crossing the side of a hill. See
page 48.
Never attempt to turn the Tractor around on
any hill until you've mastered (on level
ground) the turning technique outlined in this
manual.
Use the front hitch for vehicle recovery or
towing only. Always remove the front hitch
before operating in forward gear. See page
26.

14
SAFETY
Rider 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 50.
Always follow the procedures outlined in this manual for operating over
obstacles. See page 55.
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 54.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water. See page
52.

15
SAFETY
Rider Safety
Always follow the procedures outlined in this manual for driving in reverse. See
page 56.
Always use the size and type of tires
specified for your vehicle. Maintain
the proper tire pressure.
Never modify a Tractor 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.

16
SAFETY
Rider Safety
Never operate the Tractor on a frozen body of water.
Operating on paved surfaces may
affect the handling and control of the
Tractor 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 26.
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 Tractor safety,
contact an authorized Polaris Tractor dealer or visit the
Polaris web site at www.polarisindustries.com.

17
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.
7173025
Hill Operation/Hitch 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.
7175814
+
General
Alert
+
Hill Operation
and Hitch Alert
+
Age 16 Alert
<
1
6
1
6
1
6

18
SAFETY
Safety Labels and Locations
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (kPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY 420 LBS. (191 kg)
INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES.
Read Owner's Manual for more detailed loading information.
7174877
Reverse Override Alert/4X4 (AWD) Switch
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.
4X4 (AWD) SWITCH
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage. See your Owner’s Manual.
7175106
+
Reverse Override
Alert
+
“No Passenger”
Warning
+
+
Rack
Warning Rack
Warning
Tire Pressure/
Load Alert
+
+
Clutch
Cover Alert