Polaris 1999 Sportsman User Manual

OWNER’S MANUAL SUPPLEMENT

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1999 SPORTSMAN 500
PN 9914910

IMPORTANT: This is a supplement to your owner’s manual. This information should remain with your owner’s

manual at all times.

Specifications

Sportsman 500

Body Style Gen IV

Gross Vehicle Weight 1200 Lbs.

Fuel Capacity 5.25 U.S. Gallons

Gearcase Oil 32 Ounces

Engine Oil Capacity 2 Quarts

Front Rack (Maximum - Ca­pacity)

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Rear Rack 180 Lbs.

Tongue Weight 35 Lbs.

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Tow H itc h Standard

Tow Capacity 1225 Lbs.

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Turn Radius 65²

Ground Clearance 11²

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Height 47²

Length 81²

Seat Height 34²

Dry Weight 697

Wheel Base 50.50 ²

Width 46²

Drive System Type EBS

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Shift Type Side Lever (Hi/Lo-R-N)

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Gear Reduction - Low 6.69/1

Gear Reduction - Reverse 5.17/1

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Gear Reduction - Foward 3.34/1

Front Drive (ratio) 2:1

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Final Drive (ratio) 3.16:1

Center Drive (ratio) Not Applicable

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Drive Chain Not Applicable

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Front Tire 25 x 8-12

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Rear Tire 25 x 11-10

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Tire Pressure (front) 5

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Tire Pressure (rear) 5

90 Lbs.

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SPORTSMAN 500

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Front Susp. - Mac Strut 6.25²

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Rear Susp. - Progressive

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Rate Fully Independant w/

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Anti-roll Bar

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Shock Adjustment CAM

Front Brake Hydraulic Disc

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Rear Brake Hydraulic, opposed piston

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Auxiliary Brake Hydraulic, opposed piston

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Park Brake Hydraulic lock, all wheel

Engine Model Number EH50PLE-09

Engine Type 4 Cycle, Single Cylinder

Lubrication Dry Sump

Bore x Stroke 92 x 75

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Displacement 499

Compression Ratio 10:2 Full Stroke

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Engine Cooling Liquid

Alternator Output (watts) 250

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Carburetion 1/BST34

Main Jet 155

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Pilot Jet 40

Needle Jet Q-0

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Pilot Screw 25/8Turn

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Jet Needle 4HB41-3

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Ignition CDI

Timing 30 @ 3500

Spark Plug Gap .7 mm/.028 in.

Spark Plug Type NGKBKR5E

Exhaust USFS Approved

LIHeadlight (on Handlebar)

(watts)

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Headlight (on Grill) (watts) 2 single beam, 27

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Taillight (watts) 8.26

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Brake Light (watts) 26.9

3-Point Hitch Accessory

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Battery 12V 14AH

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DC Plug In - Rear Standard

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DC Socket - Forward Standard

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Electric Start Standard

High Beam Indicator Standard

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High Temp Indicator Standard

9.5²

caliper, fixed disc

caliper, fixed disc

1 single beam, 60

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Sportsman 500

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Windshield Accessory

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Low Oil Light Not Applicable

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Neutral Indicator Standard

Reverse Indicator Standard

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Speedometer Standard

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Tool Kit Standard

Sportsman 500

(Engine - EH50PLE-09)

Carburetor Jetting Clutching Chart

Altitude Ambient

Meters

(Feet)

Temperature

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-12000)

Below 0°F

(Below

-- 1 8 °C)

0° to 40°F

(--18°Cto

+5°C)

+40° to

+80°F

(+5°Cto

+26°C)

+80°F&

Above

(+26°C&

Above)

167.5 162.5 155 150

162.5 157.5 152.5 145

160 152.5 147.5 142.5

155 147.5 142.5 137.5

Altitude Shift

Meters

(Feet)

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-12000)

Weight

10MH Blue/

10 BH Blue/

10 WH Blue/

10 RH Blue/

Clutch
Spring

Green

Green

Green

Green

Driven

Helix

EBS

EBS

EBS

EBS

- Pilot screw in 1/2 turn

Speedometer

Your Polaris ATV is equipped with a new electronic speedometer which senses vehicle speed from the right hand front
wheel. The electronic speedometer measures distance in miles and kilometers as well as hours of operation. To
display each mode, press the button on the face of the speedometer once to “toggle” through the functions. Each
function will be displayed as shown:

Miles / Kilometers 00000.0
Trip Miles / Kilometers 000.0
Hours 00000.0

To reset Trip Miles / Kilometers:

1. Toggle to Trip Miles / Kilometers.

2. Hold down button approximately 4 seconds.

To change distance measurement from Miles to Kilometers or vice versa:

1. Toggle to odometer.

2. Hold down the button approximately 8 seconds until the word FARIA appears in the display, then release the
button. If the last digit in the display is a “K”, the measurement is Kilometers, if the last digit is an “M”, the
measurement is Miles.

The speedometer also includes a reverse speed limit function that limits the ATVs speed in reverse after approximate­ly 7 to 9 mph. Refer to page 35 of your ATV Owner’s Supplement for more information.

ATTENTION

Do not wash the electronic speedometer with a high pressure washer. Wash the unit by hand or with a garden
hose. High water pressure may allow water to enter the speedometer and cause damage to the electronic
components.

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The following information (page 35) of your ATV Owner’s Manual, has been revised.

Engine Electrical Switches

1. Override Switch (Reverse Speed Limit-

er) - This vehicle is equipped with a reverse

speed limiter system. To obtain additional
power while backing up, depress the over­ride button. WARNING: Never activate the
override button while throttle is open as loss
of control may result, causing severe per­sonal injury or death.

NOTE: The override switch also allows ac­tivation of Demand 4 Drive (All Wheel Drive)
in reverse, if Demand 4 Drive switch is on.

2. Main Switch - This switch must be turned

clockwise to the “on” position to start the en­gine.

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WARNING

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3. Emergency Engine Stop Switch -The

engine will not startor run when the switch is
in its “off” position. Its purpose is to provide
the operator with a quick means of engine
shutdown in case of stuck throttle or other
emergency.

NOTE: Both the main switch and the emer­gency engine stop switch shut off all electri­cal power to the entire vehicle including
lights.

4. Engine Start Button - Slide the stop switch to the center “run” position and push up to start.

Backing your ATV can be dangerous!

You could hit an obstacle or person behind you; or the vehicle could tip
over rearward on a steep incline causing severe injury or death.

Always back s lowly avoiding excessive speed and do not use thereverse
speed override switch system unless additional power is required for ve­hicle movement.

Avoid backing on steep inclines.

Avoid turning at sharp angles in reverse.

The following Throttle Lever information, taken from page 38 of your ATV Owner’s Manual, has been revised.

Engine Throttle and Choke

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttle le­ver. The throttle system is spring loaded and engine speed returns to idle when
the lever is released. This vehicle is equipped with a Polaris Electronic Throttle
Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle.
In the event the throttle cable should stick in an open position, the engine will stop
and power to the rear wheels will cease when the operator releases the throttle
lever.

Choke Lever

Refer to the engine starting procedure on page 56 for correct choke and throttle
settings during starting.

Choke

Throttle

WARNING

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is
provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle
mechanisms.

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WARNING

Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly
operating throttle could cause an accident resulting in severe injury or death.

Always contact your dealer for service repairs whenever throttle problems arise.
Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking

during riding and cause an accident.
Always check the lever for free movement and return before starting the engine and occasionally during rid-

ing.

Throttle Cable Free Play Adjustment

Throttle cable free play is adjusted at the
handlebar.

1. Slide the boots off inline cable adjuster

sleeve. Loosen adjuster locknut.

2. Turn adjuster sleeve until 1/16² to 1/8²

freeplay is achieved at thumb lever.

3. Tighten locknut and slide boots over cable adjuster until they touch at the middle point of adjuster.

Demand 4 Drive

Exclusive Demand 4 Drive System (All
Wheel Drive)

This Polaris AWD is equipped with a
unique, Polaris exclusive, Demand 4 Drive
(AWD) system which is activated by a
switch on the right handlebar. When the
switch is “off” the 4x4 is in 2 wheel drive at
all times. When the switch is “on” the 4x4
is in Demand 4 Drive and the front wheels
will automatically engage anytime the rear
wheels lose traction. When the rear
wheels regain traction, the front wheels will automatically disengage. NOTE: The override switch also allows activa­tion of Demand 4 Drive (AWD) in reverse, if Demand 4 Drive switch is on.

Boot

Adjuster
Sleeve

Locknut

AWD Switch

Boot

There is no limit to the length of time the vehicle may remain in Demand 4 Drive.

The Demand 4 Drive switch may be turned on or off while the vehicle is moving. If the switch is turned off when the
front hubs are driving they will not release until the rear wheels regain traction.

CAUTION: Do not switch on Demand 4 Drive if the rear wheels are spinning. This may cause severe drive shaft
and clutch damage. Engage the Demand 4 Drive switch before getting into conditions where front wheel drive may
be needed. If the rear wheels are spinning, release the throttle before turning the Demand 4 Drive switch on.

PN 9914910 Rev 05 12/98

Printed in U.S.A.

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