Polaris Sportsman 9922551 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
2010
Pantone 426c
Sportsman 500 Touring
International

Pantone 426c
For your nearest Polaris dealer,
visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
U.S.A.
Part No. 9922551 Rev 01
Printed in U.S.A.
GB
D
E
F
I
FI
P
S
Before you operate or ride this vehicle, read the
owner’s manual.
Lesen Sie die Bedienungsanleitung, bevor Sie
dieses Fahrzeug bedienen oder fahren.
Antes de operar o conducir este vehículo, lea el
Manual del propietario.
Lire le Manuel d’utilisation avant d’utiliser ou de
conduire ce véhicule.
Prima di usare o guidare il veícolo, leggere il
Manuale di istruzioni.
Lue aina käyttöohjekirja ennen tämän ajoneuvon
käyttöä tai ajamista.
Antes de utilizar ou andar neste veículo, leia o
Manual do proprietário.
Innan du hanterar eller kör detta fordon, läs
Handboken.
PASSENGER
UNDER
12

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

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, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris
Industries 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 Touring International Owner’s Manual
P/N 9922551

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Emission Control Systems . . . . . . . . . . . . . . . 60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 118
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 120
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121
Declaration of Conformity . . . . . . . . . . . . . . . 125
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 130
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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. See your Polaris
dealer about configuring the vehicle to be certified to tow a trailer on-
road.
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
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Equipment Modifications
We strongly recommend that consumers do not install on a Polaris vehi-
cle any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.
The warranty on your Polaris vehicle 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.
The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers, or large racks, may change the handling char-
acteristics of the vehicle. Use only Polaris-approved accessories, and
familiarize yourself with their function and effect on the vehicle.
WARNING

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
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 allow anyone under 12 years
of age to ride as a passenger on this
2-up vehicle.
Never carry more than one
passenger on this 2-up vehicle.

11
SAFETY
Rider 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.
Always inspect your 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 38.

12
SAFETY
Rider Safety
Keep both hands on the handlebars.
Keep both feet on the footrests.
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 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 43.
Never turn sharply at excessive
speeds, which can lead to vehicle
overturn.
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.

13
SAFETY
Rider Safety
Always follow the procedures
outlined in this manual for driving on
hills. See page 46. 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 15°.
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 vehicle
around on any hill until you've
mastered (on level ground) the
turning technique outlined in this
manual.
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.
>15°

14
SAFETY
Rider Safety
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.
Always follow the procedures
outlined in this manual for driving in
reverse. See page 57.

15
SAFETY
Rider Safety
Always use the size and type of tires
specified for your vehicle. Maintain
the proper tire pressure.
Never modify the 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.
Never operate the vehicle on a
frozen body of water.

16
SAFETY
Rider Safety
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 28.
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refu-
eling 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.
• Turn the fuel valve off whenever the vehicle is stored or parked.
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.

17
SAFETY
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions on each decal carefully. If a decal
becomes illegible or comes off, contact your Polaris dealer to purchase a
replacement. Replacement safety decals are provided by Polaris at no
charge. The part number is printed on the decal.
The following pages repeat the information found on each decal.
General Alert
(Multi-Lingual)
Before you operate or
ride this vehicle, read
the owner’s manual.
Hill Operation Alert
• Never operate this vehicle on HILLS
steeper than 15 degrees 15°.
• 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