Polaris Sportsman Forest 500 Series Guide

Owner's Manual
for Maintenance and Safety
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.
Sportsman Forest 500

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Phone [phone]
Part No. 9923430 Rev 01
Printed in USA
*9923430 *
Before you operate this vehicle,
read the owner’s manual

1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS owners. We proudly produce an excit-
ing 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 2011 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.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
SPORTSMAN FOREST 500 Owner’s Manual
P/N 9923430

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 34
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Emission Control Systems . . . . . . . . . . . . . . . 62
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 120
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 122
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 123
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 131
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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.
DANGER
A DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
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
Never operate this vehicle without proper instruction. Take a training
course.
For more information about safety, contact an authorized POLARIS
dealer or visit the POLARIS web site at www.polarisindustries.com.
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
equipment 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
(front or rear frame) ####
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.
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.