Polaris ATV Sportsman 500 Tractor INTL User Manual
Sportsman® 500
Tractor
2013
Owner's Manual
for Maintenance and Safety
It contains important safety information.
Operation is prohibited for those under 16 years of age.
Read this manual carefully.
This is an adult vehicle only.
GB
Before you operate this vehicle, read the
owner’s manual.
D
E
F
I
FI
P
S
Lesen Sie die Bedienungsanleitung bevor Sie
dieses Fahrzeug fahren.
Antes de conducir este vehículo, lea el
Manual del propietario.
Lire le Manuel du propriétaire avant d’utiliser
ce véhicule.
Prima di usare il veícolo, leggete il Manuale di
istruzioni.
Lue aina käyttöohjekirja ennen tämän
ajoneuvon käyttöä.
Antes de utilizar este veículo, leia o Manual do
proprietário.
Innan du kör detta fordon, läs
Handboken.
For your nearest Polaris dealer,
visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
U.S.A.
Part No. 9923938 Revision 01
Printed in U.S.A.
*9923938 *
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and
recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER® utility vehicles
• Victory Motorcycles®
• Low emission vehicles (LEVs)
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but information 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 ser-
vice needs during (and after) the warranty period.
1
POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS
Industries Inc.
Copyright 2012 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 discrepancies may result between the actual vehicle and the information presented in this publication. 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.
2013 Sportsman 500 Tractor Owner’s Manual
P/N 9923938
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Emission Control Systems . . . . . . . . . . . . . . . 68
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 124
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 126
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 127
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 134
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols 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 a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could 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.
4
INTRODUCTION
WARNING
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.
5
INTRODUCTION
####
VIN
Engine Serial Number
Key Number
CE Mark
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: ___________________________________________________________
6
SAFETY
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.
Read and understand your owner's manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.
Equipment Modifications
The warranty on your POLARIS Tractor 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.
7
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Eye Protection
Gloves
Long Pants
Boots
Helmet
Long
Sleeves
Helmet
Always wear a helmet that meets or exceeds established safety standards.
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
4
E
051039
0006.31
number will also be displayed on the label.
8
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever 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.
9
SAFETY
WARNING
<
1
6
1
6
1
6
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.
10
SAFETY
Rider Safety
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.
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.
11
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 43.
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 47.
Never turn sharply at excessive speeds,
which can lead to vehicle overturn.
12
SAFETY
Rider Safety
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.
Never attempt jumps or other stunts.
Always follow the procedures outlined in this
manual for driving on hills. See page 48.
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 51.
13
SAFETY
Rider Safety
Always follow the procedures outlined in this
manual for crossing the side of a hill. See
page 50.
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
28.
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 52.
Always follow the procedures outlined in this manual for operating over
obstacles. See page 57.
Always follow the procedures outlined in this manual for driving in reverse. See
page 58.
14
Rider Safety
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 56.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water. See page
54.
Always use the size and type of tires
specified for your vehicle. Maintain the
proper tire pressure.
SAFETY
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.
15
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 27.
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.
16
SAFETY
Hill Operation
and Hitch Alert
Age 16 Alert
<
1
6
1
6
1
6
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
General
Alert
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
17
SAFETY
Reverse Override
Alert
“No Passenger”
Warning
Rack
Warning
Rack
Warning
Tire Pressure/
Load Alert
Clutch
Cover Alert
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
Override Warning
WARNING
Improper use of override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually while in reverse.
4X4 (AWD) Caution
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
18
7175486
7175485
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.
7175378
Clutch Cover Alert
NO STEP
7173030
Rack Warning
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.
• Max. Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
7172572
19
FEATURES AND CONTROLS
Mode/Reverse
Override Switch
Main Key
Switch
4X4 Switch
Winch Switch
Momentary High-Beam
Switch
Work Light
Switch
Master Light
Switch
Switches
Master Light Switch
The master light switch must be in the ON position to allow operation of
the headlights, parking lights and taillights.
Momentary High Beam Switch
Press this switch with your left forefinger to activate the headlight high
beam. The lights will return to low beam when the switch is released.
Winch Switch
See page 62 for winch information.
Mode/Reverse Override Switch
Press the switch to toggle through the speedometer display modes
(except in reverse). See page 33. To gain additional power while operating in reverse, press the override switch before opening the throttle. This
will cancel the reverse speed limit function.
The reverse override switch also acts as a MODE switch when held
down for approximately one half second. See the instrument cluster
information beginning on page 33.
Tip: The override switch will not function as a MODE switch if the transmission
is in reverse.
Activating the override switch while the throttle is open can cause loss of control.
Do not activate the override switch while the throttle is open.
20
FEATURES AND CONTROLS
Override
Switch
Engine
Stop
Switch
Light
Switch
Horn
Switch
Hazard
Switch
Turn
Signal
Switch
Switches
Main Key Switch
End all electrical power to the vehicle.
The LIGHTS ON position turns the headlights
on. The master light switch must be on and the
engine stop switch must be in the RUN position.
Start the engine. The headlights are not on in
this position.
After starting the engine, release the key switch to the PARKING
LIGHTS ON position. The parking lights and taillights are on in
this position.
Do not attach a large key fob or key ring to the main switch. It may contact the
gas tank cap when turning, causing an interruption to the electrical system and
an unexpected engine shut-down during operation. This could result in serious
injury or death.
Engine Stop Switch
The engine will not start or run when the
switch is in the OFF position.
OFF (STOP)
Light Switch (High/Low Beam)
Use the light switch to change the headlights from high beam to low beam. The
master light switch must be on to operate
the headlights.
High Beam
Low Beam
RUN
21
FEATURES AND CONTROLS
Turn
Indicators
Work Light
Switch
Horn
Switch
Hazard
Switch
Turn
Signal
Switch
4X4 Switch
Switches
Work Light Switch
The work light switch controls a light
located in the pod. Use the light when
additional light is needed at the front of
the vehicle, but turn the work light off
when driving the vehicle (on-road).
Turn Signal Switch
Push the toggle switch either left
or right to activate the corresponding
turn signal light. The indicator on the
pod will also flash. Return the toggle to the center position and push it
inward to end the signal.
Hazard Warning Switch
Push the hazard warning switch
to cause all turn signal lights to
flash simultaneously. Use this
feature to alert others of an
emergency or other situation
requiring caution.
Horn Switch
Press the horn switch to sound
the horn.
4X4 Switch
Use the 4X4 switch to engage
ADC 4X4, 4X4 or 2X4. See page
30. The vehicle automatically
engages 4X4 when operating in
reverse if the 4X4 switch is set to
either 4X4 position.
22
FEATURES AND CONTROLS
Throttle Release Switch
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving the Tractor.
Throttle Lever
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Check the lever for
proper operation before starting the engine. Check occasionally during
operation.
Do not start or operate a Tractor with sticking or improperly operating throttle
controls. Contact your dealer for repair if throttle problems arise.
Press the throttle lever to increase
engine speed and vehicle movement.
Release the lever to reduce engine
speed and vehicle movement.
Throttle Release Switch
The throttle release switch
causes the engine to stop if
the throttle cable sticks in
an open position when the
operator releases the throttle lever.
The throttle release switch stops the engine in the event of a throttle system
malfunction. Do not modify this safety feature or replace it with other throttle
mechanisms.
23
FEATURES AND CONTROLS
Brakes
Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause the
rear wheels to skid and result in loss of control. Read this owner's manual and
understand the operation of all brake systems on this vehicle. Always use
caution whenever applying the brakes.
Foot Brake
The all-wheel foot brake is located on the
right footrest. The foot brake operates both
front and rear brakes. Press the brake pedal
down with your foot to apply the all-wheel
brakes. If the rear wheels begin to skid or
slide while using the foot brake, reduce
brake pressure.
Hand Brake Lever
The hand brake operates both front and rear
brakes. Squeeze the brake lever toward the
handlebar to apply the all-wheel brakes. If
the rear wheels begin to skid or slide while
using the brake, reduce lever pressure.
Parking Brake
1. Place the transmission in PARK.
2. Squeeze the brake lever toward the han-
dlebar. Push the parking brake lock forward to engage the lock. Release the
brake lever.
3. To release the parking brake lock,
squeeze and release the brake lever.
Foot Brake
Operating the vehicle while the parking brake is engaged could result in an
accident and serious injury or death. Always release the parking brake lock
before operating.
24
FEATURES AND CONTROLS
Seat
Seat Load Adjustment
Adjust the seat spring for the comfort of a lighter or heavier operator.
Reach under the rear rack to access the adjuster. Tighten the spring for
heavier riders. Loosen the spring for lighter riders.
Load Adjuster
Measure Preload
(shown with seat removed)
Use the following table to determine the best preload measurement for
rider weight. Measure preload between the adjuster plate and the lower
spring retainer.
Rider Weight Preload Measurement
Up to 39 kg 0 mm
39-94 kg 0-32 mm
Over 94 kg 32-64 mm
Driver's seat, type Seat One:
e11*78/764*2006/96*2056*00
25
FEATURES AND CONTROLS
Height Adjustment Slots
Backrest Knobs
Seat
Seat Removal
Lift the latch bar at the rear of the seat
to release the latch. Tilt the seat slightly
rearward to disengage the seat tabs
from the rear seat base slots. Remove
the seat.
Make sure the seat is securely installed
before operating.
Seat Height Adjustment
To raise or lower the seat, remove the
seat and reposition the seat tabs in one
of the rear seat base slots. Make sure the
seat is securely installed before operating.
Backrest Adjustment
Loosen the backrest knobs on each side
of the backrest mount and slide the
backrest forward or rearward to the
desired position. Tighten the knobs
securely.
26
FEATURES AND CONTROLS
Steering Lock
Lock the steering to prevent unauthorized use or theft of the vehicle.
The handlebars are locked in the fully turned position when the steering is
locked. Always unlock the steering before starting the engine.
1. Turn the handlebars to the full right or
full left position.
2. Insert the steering lock key and turn it
clockwise. Remove the key.
3. Place the steering lock keys in a safe
place. The lock must be replaced if the
keys are lost.
4. Reverse the procedure to unlock the
steering.
Fuel Tank Cap
Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded
or unleaded gasoline with a minimum pump octane of 87. Do not use E-
85 fuel.
27
FEATURES AND CONTROLS
Hitches
See page 124 for hitch weight capacities.
Front Hitch
Use the front hitch for vehicle recovery or towing only. Do not use the
front hitch for any other purpose. Always remove the front hitch before
operating in forward gear.
Rear Hitch
Hitch specifications may differ from vehicle capacity specifications. Do
not exceed the hitch and towing capacities specified for this vehicle. See
page 124.
Use the rear hitch for towing a trailer. See pages 59-61 for procedures.
Rear Hitch Specifications
Material 1021 M Steel
Fasteners 1008K Steel (Main Pin and Receiver Pin)
Weld Length and Positions 3 mm fillet, both sides, all around
Maximum Vertical Load 75 kg (on coupling point)
Maximum Towable Mass 750 kg
Approval # e11*89/173*2006/26*2073*xx
28
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