Polaris ATV Sportsman Forest 500 User Manual
Sportsman Forest 500
Owner's Manual
for Maintenance and Safety
Read this manual carefully. It contains important safety information.
Operation is prohibited for those under 16 years of age.
This is an adult vehicle only.
Before you operate this vehicle,
read the owner’s manual
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Phone 1-888-704-5290
Part No. 9923174 Rev 01
Printed in USA
*9923174 *
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 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 service
needs during (and after) the warranty period.
For more information about POLARIS, visit us online at
www.polarisindustries.com.
1
POLARIS, THE WAY OUT and SPOR TSMAN are registered trademarks of POLARIS
Industries Inc.
Copyright 2010 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 in acc uracies. 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.
Printed in U.S.A.
SPORTSMAN Forest 500 Owner’ s Manual
P/N 9923174
2
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
Declaration of Conformity. . . . . . . . . . . . . . . 127
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 131
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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 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.
4
INTRODUCTION
WARNING
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 information 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.
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.
5
INTRODUCTION
VIN
(front or rear frame)
####
Engine Serial Number
Key Number
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
WARNING
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. 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 carry a passenger. The purpose of the long
seat is to allow the operator to shift position.
7
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.
8
Operator Safety
Always inspect your POLARIS 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 53.
Keep both hands on the handlebars. Keep
your feet on the footrests.
Always travel slowly when operating on
unfamiliar terrain. Use extra caution.
SAFETY
Always follow the procedures outlined in this
manual for turning. See page 19.
Never turn sharply at excessive speeds,
which can lead to vehicle overturn.
9
SAFETY
Operator Safety
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.
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 25.
Always follow the procedures outlined in this
manual for driving on hills. See page 22.
Always follow the procedures outlined in this
manual for driving downhill and for braking on
hills. See page 25.
Always follow the procedures outlined in this
manual for crossing the side of a hill. See
page 24.
Never attempt to turn the vehicle around on
any hill until you've mastered (on level
ground) the turning technique outlined in this
manual.
10
SAFETY
Operator 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 26.
Always follow the procedures outlined in this manual for operating over
obstacles. See page 21.
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 20.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water. See page
28.
11
SAFETY
Operator Safety
Always follow the procedures outlined in this manual for driving in reverse. See
page 31.
Always use the size and type of tires
specified for your vehicle. Maintain the proper
tire pressure.
Never modify this POLARIS 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.
12
SAFETY
Operator Safety
Never operate the vehicle on a frozen body of water unless you have
independently verified that the ice is sufficiently thick to support the weight and
moving force of the vehicle, you and your cargo, together with any other
vehicles in your party.
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 40.
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.
13
SAFETY
General
Alert
Hill
Operation
Alert
Age 16
Alert
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.
Hill Operation 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.
14
SAFETY
“No Passenger”
Warning
Rack
Warning
Rack
Warning
Tire Pressure/
Load Alert
Clutch Cover Alert
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.
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING
MACHINE, DRIVER AND CARGO IS 1200 LBS. (546 kg). Read Owner's
Manual for more detailed loading information.
Clutch Cover Alert
NO STEP
Rack Warning, Front and Rear
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. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
Reverse Override Alert
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 AWD. See Owner's Manual.
15
SAFETY
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
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
number will also be displayed on the label.
16
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.
17
SAFETY
Driving Safely
Driving Procedures
1. Sit upright. Keep your feet on the footrests. Keep both hands on the
handlebars.
2. Apply the brakes.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear.
5. Check your surroundings and determine your path of travel.
6. Release the brakes.
7. Slowly squeeze the throttle lever toward the handlebar to begin
driving.
8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
18
SAFETY
Driving Safely
Turning the Vehicle
1. Before turning, activate
a turn signal to alert
others of your intentions. Activate the left
signal before a left
turn. Activate the right
signal before a right
turn.
2. Steer in the direction of
the turn, leaning your
upper body to the
inside of the turn while
supporting your weight
on the outer footrest.
Use the same leaning
technique for turning
in reverse.
3. Practice turning at slow speeds before attempting to turn at faster
speeds.
Always follow the procedures outlined in this
manual for turning. Never turn sharply at
excessive speeds, which can lead to vehicle
overturn.
19
SAFETY
Sideways
skid
Turn in direction
of skid
Driving Safely
Driving on Slippery Surfaces
Whenever driving on
slippery or loose surfaces
such as wet trails, gravel,
snow or ice, follow these
precautions:
1. Slow down before
driving onto slippery
surfaces.
2. Engage AWD before
wheels begin to lose
traction.
3. Be alert. Watch the
trail. Avoid quick,
sharp turns.
Tip: To correct a rear wheel
skid, turn the handlebars in the same direction as the skid and shift
body weight forward.
NOTICE: Severe damage
to the drive train
may occur if AWD
is engaged while
the wheels are
spinning. Engage
AWD when the wheels have traction.
Always follow the procedures outlined in this
manual for operating on slippery or loose
surfaces. Use extra caution. Always avoid
skidding or sliding.
20
SAFETY
Driving Safely
Driving Over Obstacles
1. Always check for obstacles before operating in a new area. Serious
injury or death can result if your vehicle comes in contact with a
hidden obstacle.
2. Be alert. Watch the terrain. Use extra caution.
3. Never operate over large obstacles.
4. Avoid hazards such as logs, rocks and low branches.
Always follow the procedures outlined in this manual for operating over
obstacles.
21
SAFETY
25 Maximum
Driving Safely
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Avoid steep hills (25 maximum).
2. Check the terrain carefully.
3. Avoid hills with excessively slippery or loose surfaces.
4. Shift your weight uphill.
5. Drive straight uphill.
6. Keep your feet on the footrests.
7. Drive at a steady rate of speed to avoid stalling.
8. Be alert. Be prepared to take emergency action. This may
include dismounting quickly.
9. Never open the throttle suddenly or make sudden gear changes.
10. Never go over the top of a hill at high speed.
22
SAFETY
Driving Safely
Driving Uphill
If all forward speed is lost:
Keep your weight uphill.
If the vehicle begins rolling downhill, never apply engine power. Never
apply the brakes aggressively while rolling backwards.
Apply the brakes gradually. When fully stopped, lock the hydraulic
parking brake. See page 39.
Dismount on the uphill side, or to either side if the vehicle is pointed
straight uphill. Turn the vehicle around using the K-Turn. See page 26.
Always follow the procedures outlined in this
manual for climbing hills. Avoid climbing hills
steeper than 25.
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.
23
SAFETY
Driving Safely
Driving on a Sidehill (Sidehilling)
Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is
necessary, follow these precautions:
1. Slow down.
2. Avoid hills with excessively slippery or loose surfaces.
3. Shift your weight uphill.
4. Avoid crossing the sides of steep hills.
5. Keep your feet on the footrests.
6. Steer slightly into the hill.
7. If the vehicle begins to tip, quickly turn the front wheels downhill
(if possible) or dismount on the uphill side immediately!
Always follow the procedures outlined in this
manual for crossing the side of a hill.
Never attempt to turn the vehicle around on
any hill until you've mastered (on level
ground) the turning technique outlined in this
manual.
24
Driving Safely
Driving Downhill
When driving downhill, follow
these precautions:
1. Check the terrain carefully.
2. Avoid hills with
excessively slippery or
loose surfaces.
3. Never drive downhill at
high speed.
4. Slow down.
5. Avoid driving downhill at
an angle, which can cause
the vehicle to pitch sharply
to one side. Drive straight
downhill.
6. Shift your weight rearward.
7. Apply the brakes slightly to aid in slowing.
Always follow the procedures outlined in this
manual for driving downhill and for braking on
hills.
SAFETY
Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.
25
SAFETY
2.4 m
Driving Safely
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
1. Stop the vehicle. Keep your weight uphill.
2. Lock the hydraulic parking brake.
3. Leave the transmission in forward gear. Turn the engine off.
4. Dismount on the uphill side of the vehicle, or on the left if the vehi-
cle is pointing straight uphill.
5. Stay uphill of the vehicle and turn the handlebars full left.
6. Squeeze the brake lever to release the parking brake.
7. Slowly release the brake lever and allow the vehicle to roll around
26
to your right until it's pointing across the hill or slightly downward.
SAFETY
Driving Safely
Turning Around on a Hill (K-Turn)
8. Lock the hydraulic parking brake.
9. Remount from the uphill side. Keep your weight uphill.
10. Apply the foot brake.
11. With the transmission still in forward, start the engine.
12. Squeeze and release the brake lever to release the parking brake.
13. Release the foot brake and drive slowly downhill. Control speed
with either the hand or foot brake until the vehicle is on level
ground.
Always follow the procedures outlined in this
manual for climbing hills. See page 22.
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.
27
SAFETY
Maximum Depth
Driving Safely
Driving Through Water
Follow these procedures when driving through water:
1. Check water depth and current before crossing.
2. Avoid operating in water deeper than the bottom of the footrests. If
it's unavoidable, travel slowly, balance your weight carefully and
avoid sudden movements. Maintain a slow and steady forward
motion. Do not make sudden turns, stops or throttle changes.
3. Choose a crossing where both banks have gradual inclines.
4. Drive slowly. Avoid rocks and obstacles.
5. Wet brakes may have reduced stopping ability. Always test your
brakes after leaving water. If necessary, apply them lightly several
times to allow friction to dry out the pads.
28
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