Polaris ATV Sportsman Forest 500 User Manual

Download

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.

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

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

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.

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.

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: ___________________________________________________________

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.

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.

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.

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.

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.

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.

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.

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.

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.

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

SAFETY

Driving Safely

Driving Through Water

If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 100. Have the vehicle serviced by your dealer promptly.

If water has been ingested into the transmission (PVT), follow the procedure on page 105.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water.

If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

SAFETY

Driving Safely

Parking on an Incline

Avoid parking on an incline. If it's unavoidable, follow these precautions:

1. Stop the engine.

2. Place the transmission in PARK.

3. Always block the rear wheels on the downhill side.

4. Turn the fuel valve off.

SAFETY

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Avoid backing downhill.

2. Always check for obstacles or people behind the vehicle before

backing.

3. Drive slowly.

4. Apply the foot brake lightly for stopping.

5. Avoid turning at sharp angles.

6. Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

Tip: Reverse speed is greatly increa sed when the override switch is used. Do

not operate at full throttle. Apply just enough throttle to maintain the desired speed.

Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

Always follow the procedures outlined in this manual for driving in reverse.

SAFETY

Driving Safely

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo.

• Read and understand the load distributio n warnings listed on the vehicle warning labels.

• Never exceed the stated load capacity for this vehicle.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes. Avoid situations that require backing downhill.

• When operating over roug h or hilly terrain, reduce speed, cargo and towed load to maintain stable driving conditions.

• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

• CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. Reduce load weight when cargo is high. Secure off-centered loads that cannot be centered and operate with extra caution.

• CARRYING A LOAD on only one rack may cause the vehicle to overturn. Split the load between the front rack and rear rack, with 1/3 in the front and 2/ 3 in the back. Do not exceed load capacities. See specifications beginning on page 120.

• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

• USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

• TOWING is approved OFF-ROAD ONL Y. Operating this vehicle with a trailer on public roads is prohibited.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when towing loads in rough terrain, while cornering, or while ascending or descending hills.

SAFETY

1/3

2/3

Maximum

17 cm

Driving Safely

Hauling Cargo

Towing Loads

Towing is approved OFF-ROAD ONLY. Operating this vehicle with a trailer on public roads is prohibited. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15.

Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your warranty. Never install a hitch longer than 17 cm. Never install automotive accessories on your POLARIS vehicle. Always install POLARIS-approved (or equivalent) accessories designed for use on the vehicle.

FEATURES AND CONTROLS

Mode/Reverse

Override Switch

Main Key

Switch

All Wheel Drive

Switch

Choke

Winch Switch

Momentary High-Beam

Switch

Switches

Mode/Reverse Override Switch

Press the switch to toggle through the speedometer display modes (except in reverse). See page 45.

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 override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on.

Activating the override switch with the throttle open and while operating in reverse can cause loss of control. Do not activate the override switch while the throttle is open.

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.

All Wheel Drive Switch

See page 44 for all wheel drive information.

Winch Switch

See page 56 for winch information.

FEATURES AND CONTROLS

Override

Switch

Engine

Stop

Switch

Headlight

Switch

Horn

Switch

Hazard

Switch

Turn

Signal

Switch

Switches

Main Key Switch

End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position.

After starting the engine, release the key switch to the POSITION LIGHTS ON position.

See page 54 for starting procedures.

Engine Stop Switch

The engine will not start or run when the switch is in the OFF position.

OFF RUN

Headlight Switch

The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position.

High Beam Low Beam

FEATURES AND CONTROLS

Horn

Switch

Hazard

Switch

Turn

Signal

Switch

Switches

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 to end the signal.

Horn Switch

Press the horn switch to sound the

horn.

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.

FEATURES AND CONTROLS

Electronic Throttle Control

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle.

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 vehicle 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.

Electronic Throttle Control (ETC)

ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.

FEATURES AND CONTROLS

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.

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.

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in

PARK.

2. Squeeze the brake lever

toward the handlebar.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

5. To rele ase the parking brake

lock, squeeze and release the brake lever.

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.

FEATURES AND CONTROLS

Steering Lock

Lock the steering to prevent unauthorized use or theft of the vehicle.

Tip: Place the steering lock keys in a

safe place. The lock must be replaced if the keys are lost.

1. Turn the handlebars to the full

left position.

2. Insert the steering lock key

and turn it clockwise.

3. Remove the key.

4. Reverse the procedure to

unlock the steering.

The handlebars are locked in the full left position when the steering is locked. Always unlock the steering before starting the engine.

Fuel Valve

OFF

Fuel

Valve

Fuel

Tank

Cap

The fuel valve is located under the front storage box cover.

OFF: For vehicle storage and when transporting.

ON: For normal operation.

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 54 for correct choke and throttle settings during starting.

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

Fuel Tank Cap

This vehicle is equipped with a digital fuel gauge that will indicate a low fuel condition. Refuel when the gauge indicates a low fuel condition.

Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface.

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/

2) octane. Do not use fuel with etha-

nol content greater than 10 percent, such as E-85 fuel.

FEATURES AND CONTROLS

Gear

Selector

Transmission Gear Selector

The transmission gear selector is located on the right side of the vehicle.

H: High Gear L: Low Gear N: Neutral R: Reverse P: Park

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear .

Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage.

Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK.

Belt Life

To extend belt life, use low forward gear when pulling a heavy load at less than 11 km/h for extended periods and when operating uphill at a slow speed.

FEATURES AND CONTROLS

Recoil Starter

Handle

Recoil Starter (if equipped)

If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 54, cranking the engine with the recoil starter instead of the main key switch.

1. Grasp the recoil starter rope

handle tightly.

2. Pull slightly until the starter

mechanism engages.

3. Pull the rope abruptly to start the engine.

Extending the recoil starter rope until it stops can cause damage to the recoil assembly. Do not extend the starter rope so far that it stops.

If the starter rope handle is not seated properly, water may enter the recoil housing and damage components. Make sure the handle is fully seated on the recoil housing, especially when traveling in wet areas.

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

The AWD switch may be turned on or off while the vehicle is moving. AWD will not engage until engine speed is below 3100 RPM. AWD remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in AWD.

If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction. Engage A WD before getting into situations where maximum traction is needed. If the rear wheels are spinning, release the throttle before switching to AWD.

Tip: The override switch al lows activation of AWD in reverse if the AWD switch

is on. See page 34.

Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest.

AWD

When the AWD switch is on, the vehicle is in four-wheel drive and the differential is locked, providing maximum traction. The demand drive unit automatically engages when the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit automatically disengages.

2X4

When the 2X4 switch is on, the vehicle is in two-wheel drive at all times and the differential is locked.

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Speedometer

Instrument Cluster

Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists.

The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 34 for additional information.

High water pressure may damage vehicle components. Wash the vehicle by hand or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster . All segments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis.

1. Gear Indicator - This

indicator displays gear shifter position: H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park

2. AWD Indicator - This

indicator illuminates when the AWD switch is in the AWD position.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Odometer/Tachometer/Tripmeter/ Hour Meter

6. Fuel Gauge - The segments of the fuel gauge show the level of fuel

in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, FUEL will display in the LCD, and the speedometer needle will blink. Refuel immediately.

7. Check Engine Warning Indicator - The word HOT displays if the

engine overheats. Do not operate the vehicle if this warning appears. Serious engine damage could result.

8. Mode Indicator

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 34.

NOTE: The transmission cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0.

NOTE: In the Rider Information Center, the trip meter display contains a deci-

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Tachometer Mode

The engine RPM is displayed digitally.

NOTE: Small fluctuations in the RPM from day to day may be normal because

mal point, but the odometer displays without a decimal point.

of changes in humidity, temperature and elevation.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Lock the parking brake.

3. Place the transmission in neutral.

4. Hold the mode/reverse override button and turn the key switch on.

Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the diagnostic screens.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

AWD Diagnostic Screen

The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). This screen is for informational purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. This screen is for informational purposes only. Please see your dealer for all major repairs.

Programmable service interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. See page 50.

The service interval is programmed at 50 hours at the factory.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about 7 seconds, until either ON

or OFF appears in the Rider Information Center, depending on your preference.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for 2-3 seconds, until the wrench

icon flashes. Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours quickly.

5. If you scroll past the intended number, press and hold the button

until the hours cycle back to zero.

6. When the desired setting is displayed, wait until the wrench icon

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM) or miles

(MP).

3. Press and hold the mode button until the letters flash, then press and

release the button once. When the display stops flashing, the mode has been set.

OPERATION

WARNING

Fuel Safety

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 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.

OPERATION

Break-In Period

The break-in period for your new POLARIS vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and performance of your vehicle more than following the procedures for a proper breakin. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with the recommended fuel. See page 41.

2. Check the oil level. Add oil if necessary.

3. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

4. Drive slowly . Vary the throttle positions. Do not operate at sustained

idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 53.

6. Pull only light loads.

7. Change the oil and filter at 20 hours or one month.

PVT Break-in (Clutches/Belt)

Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

OPERATION

Pre-Ride Checklist

Item Remarks Page

Foot brake Ensure proper operation 38 Hand brake/lever travel Ensure proper operation 85 Brake fluid Ensure proper level 82 Front suspension Inspect, lubricate if necessary 68 Rear suspension Inspect, lubricate if necessary 68 Steering/steering lock Unlock the steering; ensure free oper-

Tires Inspect condition and pressure 90 Wheels/fasteners Inspect, ensure fastener tightness 90 Frame nuts, bolts, fasteners Inspect, ensure tightness Fuel and oil Ensure proper levels 41

Throttle Ensure proper operation 37 Indicator lights/switches Ensure proper operation 34

Engine stop switch Ensure proper operation 35 Mirrors Adjust for best side/rear vision 37 Air filter, pre-filter Inspect, clean 92 Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply POLARIS

Brake light/tail lamp Check operation, apply POLARIS

Riding gear Wear approved helmet, goggles, and Winch Inspect cable and switch. 57-58

ation

dielectric grease when lamp is replaced

protective clothing

70 89

OPERATION

Tension

Adjusting Nut

Starting the Engine

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.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Turn the fuel valve on.

4. Sit on the vehicle.

Tip: The starter interlock will prevent the engine from starting if the transmission

is in gear and the brake is not engaged.

Tip: Do not use the choke if starting a warm engine. Excessive use of the choke

can cause the spark plug to become wet fouled.

5. If the engine is cold, pull the choke

knob out until it stops. If the knob doesn't stay where positioned, increase the tension by rotating the tension adjusting nut clockwise.

Tip: The va riable choke is fully on when the

knob is pulled completely out. The choke is off when the knob is pushed completely in. The choke can be adjusted gradually, depending on how much choke is needed for starting. Be sure the choke is off during operation, as excess fuel washing into the engine oil will increase wear on engine components.

6. Move the engine stop switch to RUN.

OPERATION

Starting the Engine

7. Do not press the throttle while starting the

engine. Turn the ignition key past the POSITION LIGHTS ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

8. If the engine does not start, release the

starter and wait five seconds.

9. Repeat steps 7 and 8 until the engine starts.

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating.

10. If a warm engine has cooled to a point where it does not readily

start, intermittent use of the choke (pulled half way out) may be necessary. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in starting. Release the throttle lever immediately after the engine starts. If the engine does not start and all conditions are favorable, change the spark plug and try again.

11. If the engine slows or stops, position the choke knob half way in to

allow proper engine warm up. Vary the engine RPM slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke completely in.

Cold Weather Operation

Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained. W ater accumulation increases as outside temperature decreases.

See your POLARIS dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

WINCH GUIDE

WARNING

DANGER

Danger Zone

The responsibility for safe operation of the winch ultimately rests with you, the operator. Read and understand all safety precautions and operating instructions before operating the winch. Careless operation can result in serious injury. DO NOT use the winch to lift or move people.

Winch Safety Precautions

1. Be alert. Do not operate the winch under the influence of drugs,

alcohol or medication.

2. Practice using the winch so you are prepared to use it in an emer-

gency situation.

Never connect DC powered winches to AC current. Motor damage or fatal shock may occur.

Stand clear of the cable and load during winching. Keep helpers and spectators at a safe distance. If a cable pulls loose or breaks under the load, it can lash back with dangerous force.

3. Beware of the danger zone.

The danger zone is the area of the rotating wire cable drum, the fairlead (if fitted), the cable, the hook and the motor. Before placing hands in or near the danger zone, first relieve tension on load, then disconnect the control switch.

4. If you are within four feet of the winch, do not hold the cable and

the remote (if equipped) at the same time.

WINCH GUIDE

Winch Cable Care

1. The life of a cable is directly related to the care it receives. The wire

cable on a new winch (and any replacement cables) must be respooled under a minimum of a 100-lb. (45.4-kg) load before use. Failure to do this will result in cable damage.

2. Inspect all cable before use. Mashed, pinched, frayed or kinked

areas severely reduce the load-carrying capability. Replace damaged cable promptly.

3. Prevent kinks before they occur.

A. This is a start of a kink. Straighten

the cable before using it.

B. The cable was pulled and the loop

has tightened to a kink. The cable is now permanently damaged and should not be used.

C. The result of kinking is that each

strand pulls a different amount of load, causing the strands under the greatest tension to break. This reduces the load capacity of the entire cable.

4. Before re-spooling, remove all load from the cable. Hold the han-

dlebar switch lead in one hand and the cable in the other. Move away from the vehicle as far as the switch will allow. Activate the switch, walk in several feet of cable, then release the switch. Repeat this process until the re-spooling is complete.

CAUTION! To avoid injury, always release the switch before your hand comes within four feet of the fairlead (the physical opening through which the cable passes).

5. Be sure the cable is distributed evenly and tightly on the drum. A

loosely wound drum may allow the cable to work its way down into the layers of cable on the drum and become wedged.

6. Do not grease or oil the cable. Doing so causes dirt contamination

that will reduce the life of the cable.

WINCH GUIDE

DANGER

WARNING

DANGER

Winch Preparation and Inspection

Wear heavy leather gloves whenever handling cable. Do not allow the cable to slip through your hands, even with gloves on. When handling the hook, always use a handsaver. Never place fingers into the hook. Placing fingers in the hook could result in injury.

Inspect the switch and wiring for cracks, pinched spots, frayed wire or loose connections. A damaged, shortened lead could cause the winch to operate as soon as it is plugged in.

Never touch the cable or hook while they are in tension or under load. Even at rest, the winch may have the cable in tension. Never guide a cable under tension onto the drum with your hand.

1. Winch with at least five wraps of cable around

the winch drum. With fewer wraps, the cable could pull loose from the drum under load.

WINCH GUIDE

WARNING

Winch Rigging

Take your time when rigging and use extra caution. Improper rigging can result in injury in addition to damage to the vehicle and equipment. Never handle the cable or rigging while another person is at the control switch.

1. Use a nylon sling to

attach the cable to an anchor point.

CAUTION! Do not attach the hook back onto the cable. Doing so can cause the cable to break.

Always use a handsaver. Do not hold the hook with your hand. This is important not only when reeling cable in but also when removing cable from the winch under power.

2. Run the winch intermittently to take

up cable slack. When using a pulley block, be sure the cable is running properly in all pulleys before applying a load.

CAUTION! Never engage or disengage the clutch if the winch is under load, the cable is in tension or the drum is rotating.

WINCH GUIDE

Winch Operation

NOTICE: This winch is designed for intermittent use. Prolonged use may result

1. Use common sense.

2. Take your time.

3. Think through the situation.

4. Pay attention to what is going on when you are winching.

5. DO NOT overheat the winch motor. During extended winching,

6. Extended winching will discharge your battery. If the low battery

7. DO NOT overload or stall the winch. If the load is greater than the

8. Avoid continuous side pulls.

9. Never tow the vehicle by the winch cable.

10. Never use the winch cable as a tie-down.

11. Use an anchor point that is stronger than what you are pulling.

12. DO NOT hook the cable back onto itself. This will damage the

in damage due to overheating.

stop and feel the winch motor. The motor should be cool enough to touch. If not, allow the motor to cool before continuing.

warning light comes on, stop winching. Make sure the transmission is in neutral or park, then rev the motor for a few minutes until the warning light goes out. Recharge the battery as soon as possible.

winch is capable of pulling, use a snatch block.

cable.

WINCH GUIDE

Winch Operation

13. Use as much cable as possible when pulling. Additional wraps of

cable on the spool will significantly reduce the pulling power of your winch. If the winch is still not capable of pulling the load, use a snatch block.

14. Never pull with less than five wraps of cable on the spool.

15. Inspect the condition of the cable prior to pulling. If the cable is

frayed or damaged, replace it as soon as possible.

16. DO NOT submerge the winch in water.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

Spark Arrestor

Your POLARIS vehicle has a spark arrestor that was designed for onroad and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at POLARIS specifications to achieve optimal performance.

Engine idle speed is the only adjustment POLARIS recommends that the operator perform. Any other adjustments should be performed by an authorized POLARIS dealer.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/EC. Non-ionizing Radiation: This vehicle emits some electromagnetic

energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

MAINTENANCE

Periodic Maintenance Chart

Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently.

The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 45.

Record maintenance and service in the Maintenance Log beginning on page 131.

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold

weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

MAINTENANCE

WARNING

Periodic Maintenance Chart

Improperly performing the procedures marked with a  could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized POLARIS dealer perform these services.

Maintenance Chart Key

 Perform these operations more often for vehicles subjected to

severe use.

E Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

 Have an authorized POLARIS dealer perform these services.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering - Pre-Ride - Make adjustments as need Front suspension - Pre- Ride Rear suspension - Pre-Ride Tires - Pre- Ride Brake fluid level - Pre-Ride Brake lever - Pre-Ride Foot brake - Pre-Ride Brake system - Pre-Ride Wheels/fasteners - Pre-Ride Frame fasteners - Pre- Ride -

 Engine oil level - Pre-Ride -

Winch - Pre-Ride - See pages 57-58.



Air filter, pre-filter - Daily - Inspect; clean often; replace

 Air box sediment

tube Coolant - Daily - Check level daily, change

Headlight/taillight - Daily - Check operation; apply



Air filter,

main element Recoil housing

(if equipped)

Brake pad wear 10 Monthly 160 Inspect periodically





Battery 20 Monthly 300 Check terminals; clean; test

 Demand drive fluid

(front gearcase)

 Rear gearcase oil

(if equipped)

 Transmission oil 25 Monthly 400 Inspect level; change yearly 

Engine breather

filter (if equipped)

 Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

 Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Kilometers

ed. See Pre-Ride Checklist on page 53.

as needed

- Daily - Drain deposits when visible

coolant every 2 years

dielectric grease if replacing

- Weekly - Inspect; replace as needed

- Weekly - Drain water as needed,

25 Monthly 400 Inspect level; change yearly

25 Monthly 400 Inspect; clean if needed

check often if operating in wet conditions

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

 Engine oil change

(break-in)

 General

lubrication Shift linkage 50 6 M 800 Inspect, lubricate, adjust



Steering 50 6 M 800 Lubricate

 Front suspension 50 6 M 800 Lubricate  Rear suspension 50 6 M 800 Lubricate

Carburetor float bowl



Throttle Cable/

ETC Switch



Choke cable 50 6 M 800 Inspect; adjust; lubricate;

E E Carburetor air

intake ducts/flange Drive belt 50 6 M 800 Inspect; adjust; replace as

Cooling system 50 6 M 800 Inspect coolant strength

 Engine oil change 100 6 M 1600 Perform a break-in oil change

 Oil filter change 100 6 M 1600 Replace with oil change  Oil tank vent hose

(if equipped)



Valve clearance 100 12 M 1600 Inspect; adjust



Fuel system 100 12 M 1600 Check for leaks at tank cap,

Fuel filter 100 12 M 1600 Replace annually





 Radiator 100 12 M 1600 Inspect; clean external

 Cooling hoses 100 12 M 1600 Inspect for leaks  Engine mounts 100 12 M 1600 Inspect

Exhaust muffler/ pipe

(whichever comes first)

Hours Calendar Kilometers

- 1 M - Perform a break-in oil change

50 3 M 800 Lubricate all fittings, pivots,

50 6 M 800 Drain bowl periodically and

50 6 M 800 Inspect; adjust; lubricate;

50 6 M 800 Inspect duct for proper seal-

100 6 M 1600 Inspect routing, condition

100 12 M 1600 Inspect

at one month

cables, etc.

prior to storage

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at one month

lines, fuel valve, filter, pump, carburetor; replace lines every two years

surfaces

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval



Spark plug 100 12 M 1600 Inspect; replace as needed

 Wiring 100 12 M 1600 Inspect for wear, routing,



Clutches (drive and driven)



Front wheel bearings



Brake fluid 200 24 M 3200 Change every two years Spark arrestor 300 36 M 4800 Clean out



Toe adjustment - Inspect periodically; adjust



Brakes - Inspect daily; adjust as

Headlight aim - Adjust as needed

 Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

 Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Kilometers

security; apply dielectric grease to connectors subjected to water, mud, etc.

100 12 M 1600 Inspect; clean; replace worn

100 12 M 1600 Inspect; replace as needed

parts

when parts are replaced

needed

Remarks

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Guide

Always check and change fluids and lubricate greaseable components at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. Items not listed in the chart should be lubricated at the General Lubrication interval.

Item Lube Method

Engine Oil PS-4 PLUS Performance

Brake Fluid DOT 4 Only See page 82. Transmission Oil AGL PLUS Transmission

Front Demand Drive Unit (Front Gearcase)

Front Prop Shaft Yoke POLARIS Premium U-Joint

Synthetic 2W-50

Fluid

Demand Drive Plus Fluid See page 77.

Lube

See page 69.

See page 75.

Grease fittings (3 pumps maximum) every 800 km, before long periods of storage, or after pressure washing or submerging.

MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing oil. POLARIS recommends the use of POLARIS PS-4 PLUS Performance

Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 122 for the part numbers of POLARIS products.

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use a recommended oil. Never substitute or mix oil brands.

Oil Specifications

Model Lubricant Capacity Drain Plug Torque

SPORTSMAN

Forest 500

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle

Oil

1.9 liters 19-23 N-m

MAINTENANCE

Dipstick

Safe

Add Oil

Safe Range

{

Engine Oil

Oil Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for 30 seconds.

4. Stop the engine.

5. Remove the dipstick.

Wipe it dry with a clean cloth.

6. Reinstall the dipstick

completely.

7. Remove the dipstick and check the oil level. Add oil as needed.

Maintain the oil level in the safe range. Do not overfill.

8. Reinstall the dipstick.

MAINTENANCE

Drain

Plug

New Sealing Washer

Screen

Fitting

Engine Oil

Oil Change

Hot oil may result in serious burns. Do not allow hot oil to contact skin.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for two minutes.

4. Stop the engine.

5. Clean the area

around the drain plug.

6. Place a drain pan

under the oil tank.

7. Remove the drain

plug.

8. Drain the oil.

9. Clean the drain plug. Reinstall the drain

plug with a new sealing washer.

10. Torque to specification. See page 69.

MAINTENANCE

Alignment Mark

Engine Oil

Oil Change

11. Disconnect the lower oil deliv-

ery hose and remove the screen fitting from the oil tank. Clean the fitting. The fitting threads

must be sealed with LOCTITE PST 505 or PTFE seal tape.

12. Reinstall the screen fitting and

rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank.

Tip: Do not over-tighten. Maximum to rque for the screen fitting is 34 N-m.

13. Reattach the oil line.

14. Place towels under the oil filter.

Using an oil filter wrench, turn the filter counter-clockwise to remove it.

15. Clean the filter sealing area on the

crankcase.

16. Lubricate the filte r o-ring. Check to make

sure the o-ring is in good condition.

17. Install the new oil filter. After the filter

contacts the crankcase surface, turn it 1/2 turn by hand.

18. Approximately 240 ml of engine oil will remain in the crankcase.

To drain, remove the drain plug on the lower right side of the crankcase.

Tip: The sealing surfaces on the drain plug and crankcase should be clean and

free of burrs, nicks or scratches.

19. Reinstall the drain plug. Torque to specification.

MAINTENANCE

Safe

Add Oil

Safe Range

{

Engine Oil

Oil Change

20. Remove the dipstick.

21. Add 1.9 liters of recommended oil. If the sump is not drained, add

about 1.6 liters initially.

22. Reinstall the dipstick.

23. Place the transmiss ion in PARK.

24. Prime the oil pump using the procedure

on page 74.

25. Stop the engine. Check for oil leaks.

26. Check the oil level.

Add oil as needed. Maintain the oil level in the safe range. Do not overfill.

27. Reinstall the dipstick.

28. Discard used oil and

filter properly.

MAINTENANCE

Clamp

Pressure

Relief Slit

Tank

5 cm

Engine Oil

Oil Change

Oil Pump Priming

This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.

1. Clamp the vent line 5 cm from

the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

2. Start the engine. Allow it to idle

for 10-20 seconds.

3. Remove the vent line clamp. If

the line is bled properly, you should hear a rush of air. If you do not hear a rush of air, repeat the priming procedure.

MAINTENANCE

Fill Plug

Fill Level

Transmission Oil

Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 122 for the part numbers of POLARIS products.

Oil Recommendations

Lubricant O il Change

Capacity

AGL PLUS Transmission Fluid 948 ml 27-34 N-m 27-34 N-m

Fill Plug

Tor que

Drain Plug

Tor que

Oil Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Check the oil level. Maintain the

level at the bottom of the fill hole threads.

5. Add the recommended oil as needed.

Do not overfill.

6. Reinstall the fill plug. Torque to

specification.

MAINTENANCE

Drain Plug

Transmission Oil

Oil Change

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Remove the drain plug.

5. Drain the oil into a drain pan.

6. Clean the drain plug.

7. Reinstall the drain plug. Torque

to specification. See page 75.

8. Add the recommended oil.

9. Reinstall the fill plug. Torque to

specification.

10. Check for leaks.

11. Disca rd used oil properly.

MAINTENANCE

Drain Plug

Fill Plug

Fill Level

Front Gearcase (Demand Drive) Fluid

Fluid Recommendations

Gearcase Lubricant Capacity Fill Plug

Demand Drive

Unit

Demand Drive Plus Fluid 265 ml 11-14 N-m 15 N-m

Tor que

Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 122 for the part numbers of POLARIS products.

Maintain the fluid level at the bottom of the fill hole threads.

Fluid Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Add the recommended demand drive fluid as needed.

5. Reinstall the fill plug. Torque to specification.

Drain Plug

Tor que

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Change

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Remove the drain plug.

Drain the fluid into a drain pan.

5. Clean the drain plug.

6. Reinstall the drain plug. Torque

to specification. See page 77.

7. Add the recommended fluid.

8. Reinstall the fill plug. Torque to

specification.

9. Check for leaks.

10. Discard used oil properly.

MAINTENANCE

Idle Screw

Carburetor

This vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation. Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient operation. Optional jets, available from your POLARIS dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.)

Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or PVT or engine damage. See your POLARIS dealer for more information about jetting the ATV for conditions in your area.

Pilot screws are sealed with metal plugs and are serviceable only by POLARIS dealers.

Carburetor/Engine Idle RPM Adjustment

Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is unsatisfactory and all other conditions are favorable, the carburetor can be adjusted.

1. Start the engine and allow it to

warm up for approximately five minutes.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Turn the screw in (clockwise) to

raise RPM. Turn the screw out (counter-clockwise) to lower RPM.

MAINTENANCE

Recovery

Bottle

Cooling System

Any time the cooling system has been drained for maintenance or repair, replace the coolant with a fresh mixture of antifreeze and water. Drain the cooling system every two years. Add fresh coolant.

POLARIS recommends the use of POLARIS Premium 60/40 antifreeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water . POLARIS Premium 60/40 is premixed and ready to use. Do not dilute with water. See page 122 for the part numbers of POLARIS products.

Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

Recovery Bottle Coolant

Some coolant level drop on new machines is normal, as the system is purging itself of trapped air. Add coolant as needed.

Tip: Check the coolant level in the radi-

ator any time the recovery bottle has run dry.

1. Check the coolant level when

the fluid is cool. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

2. Remove the left side panel. See

page 88.

3. View the coolant level.

4. Add coolant as needed.

5. Reinstall the side panel.

MAINTENANCE

Radiator

Cap

Cooling System

Radiator Coolant

Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot.

1. Remove the front box/rack.

2. Remove the radiator pressure

cap.

3. If coolant is not visible,

slowly add coolant through the radiator filler neck.

4. Reinstall the pressure cap.

Tip: Use of a non-standard pressure

cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.

5. Reinstall the front box/rack.

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.

Operating the vehicle with a spongy brake can result in loss of braking, which could cause an accident. Never operate the vehicle with spongy-feeling brakes.

If the fluid level is low add DOT 4 brake fluid only . See page 122 for the part numbers of POLARIS products.

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

Brake Fluid

Master Cylinder

Indicator

Window

Full

Low

Hand Brake

The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill.

1. Position the vehicle on a

level surface. Make sure the handlebars are straight.

2. View the fluid level

through the indicator window (eye) on the top of the master cylinder.

Tip: The eye will appear dark when

the fluid level is full. When fluid is low, the eye will be clear.

3. Add the recommended

fluid as needed. Do not overfill.

MAINTENANCE

Foot Brake Fluid

Reservoir

Brake Fluid

Foot Brake

1. Position the vehicle on a

level surface.

2. Remove the seat.

3. View the fluid level in the

master cylinder.

4. Maintain the fluid level

between the minimum and maximum marks. Do not overfill.

MAINTENANCE

1 mm

Brakes

The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting.

Brake Inspections

Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily under normal operation.

1. Always keep brake fluid at an adequate

level. See page 82.

2. Check the brake systems regularly for

fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace the pads when the friction material is worn to 1 mm.

5. Check the security and surface condition

of the disc.

MAINTENANCE

String

Stand

FRONT

Toe Alignment

Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer.

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out.

1. Position the vehicle on a

level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string

between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire. If available, you may use a long straight-edge instead of string.

4. Measure the distance

from the string to the rim at the front (1) and rear (2) of the front rim. The rear measurement should be 2-3 mm more than the front measurement on each side of the vehicle to obtain the recommended 3-6 mm toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

6. If you discover improper alignment, see your POLARIS dealer for

service.

MAINTENANCE

14-17 N-m

Adjuster

Steering Assembly

Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle.

Handlebar Adjustment

The handlebars can be adjusted for rider preference.

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.

1. Remove the upper headlight

pod.

2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the

desired height.

Tip: Be sure the handlebars do not con-

tact the gas tank or any other p a rt of the machine when turned fully to the left or right.

4. Torque the front two bolts to

14-17 N-m, then torque the rear two bolts. A gap of up to 3 mm will remain at the rear bolts.

Rear Spring Adjustment

The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension.

MAINTENANCE

Screws

Rivets

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel

near the rear cab.

3. With a firm motion, pull the

panel outward to disengage the side panel from the grommet.

4. Pull the panel downward and

rearward to remove it.

Footwell Removal

1. Remove the four screws on

the bottom of the footwell.

2. Use a flat screwdriver or

sidecutters to remove the plastic rivets securing the footwell to the fenders.

3. Remove the footwell.

Throttle Cable Freeplay

Boot

Lock Nut

Adjuster

1.6-3.2 mm

Adjust throttle cable freeplay at the handlebar.

1. Locate the throttle cable adjuster

at the handlebar.

2. Squeeze the end of the rub-

ber boot and slide it far enough to expose the end of the inline cable adjuster.

3. Loosen the adjuster lock nut.

4. Rotate the boot to turn the

adjuster until 1.6-3.2 mm of freeplay is achieved at the thumb lever. Move the throttle lever back and forth while adjusting.

MAINTENANCE

5. Tighten the lock nut.

6. Squeeze the end of the

rubber boot and slide it over the cable adjuster to its original position.

WARNING! Engine RPM should not increase when steering is turned full left or right. Readjust cable freeplay if this occurs.

MAINTENANCE

WARNING

3 mm

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident.

• Maintain proper tire pressure as described on the label on your vehicle and in the specifications section of the owner's manual.

• Use only original equipment size and type whe n replacing tires.

• Make sure the wheels are installed properly.

• Replace tires when the tread depth measures 3 mm or less.

Refer to the specifications section beginning on page 120 for recommended tire type, size and pressure.

Tire Tread Depth

Always replace tires when tread depth is worn to 3 mm or less.

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized POLARIS dealer.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loosened for maintenance service.

Nut Type Nut Torque

Lug Nut (Aluminum Wheels) 41 N-m

2-Piece Flange Nut (Steel Wheels)

PLUS 1/4 TURN

37 N-m

MAINTENANCE

Tires

Wheel Removal/Installation

Always use original equipment size and type when replacing tires. Install wheels properly.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Loosen the wheel nuts

slightly.

4. Place a suitable stand under

the footrest frame to raise the wheel slightly off the ground.

5. Remove the wheel nuts.

6. Remove the wheel.

7. Place the wheel on the hub.

8. Install the wheel nuts finger

tight.

9. Lower the vehicle to the

ground.

10. Torque the wheel nuts to

specification. See torque chart on page 90.

MAINTENANCE

Main Filter

Pre-Filter

Air Filter

Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 63.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the seat.

4. Release the air box

cover clips.

5. Remove the air

box cover.

6. Loosen the hose

clamp.

7. Remove the filter.

8. Remove the pre-filter

from the filter.

9. Wash the pre-filter in soapy water. Rinse and air dry.

10. Replace the filter if needed.

11. Reverse the steps to reinstall all components.

MAINTENANCE

Breather

Filter

Breather Filter/Hose

The breather filter is on the hose between the engine and air box.

1. Remove the left side panel.

See page 88.

2. Remove the hose clamps from

the filter and pull the filter out of the hoses.

3. Inspect the filter for debris.

Blow gently through the filter in the direction of the arrow to check for clogging. Replace a damaged or clogged filter.

4. Check the hoses for cracks, deterioration, abrasion, or leaks.

Replace as needed.

5. Reinstall the filter and hose clamps.

Tip: The filter is effective with the arrow pointing in either direction.

Operation of your vehicle without a breather filter can cause engine damage.

MAINTENANCE

7.6 m 5 cm

Lights

Headlight Beam Adjustment

The headlight beam can be adjusted slightly upward or downward.

1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall.

2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height. Include rider weight on the seat when measuring.

4. Start the engine.Turn the headlight switch to high beam.

5. Observe the headlight aim on the wall. The most intense part of the

headlight beam should be 5 cm below the mark on the wall.

6. Tighten or loosen the lower headlight screws to adjust the beam

upward or downward or to the left or right.

MAINTENANCE

Position Light

Collar

Socket

Headlamp

Lights

Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently.

Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled.

Headlight/Position Light Lamp Replacement

When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Hold the plastic part of the lamp.

1. Place the transmission in PARK.

2. Remove the front box/rack.

3. Remove the plug at the back of the headlight.

4. Pull the harness plug to disconnect it from the back of the headlight.

5. Position light: Rotate the socket to remove it. Go to step 6. Headlamp: Reach under the bumper and remove the rubber cover from the back of the headlight. Turn the collar counterclockwise and carefully remove the collar and socket.

6. Remove the lamp. Apply dielectric grease to the socket and install a new lamp.

7. Reverse all steps to reassemble the headlight.

MAINTENANCE

Lights

Taillight Lamp Replacement

1. Place the transmission in PARK.

2. Rotate the taillight socket

counter-clockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the

socket.

5. Install the new lamp. Test the lamp for proper operation.

6. Reinstall all components in reverse order.

Front Turn Signal Replacement

If a front turn signal light becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly.

Rear Turn Signal Lamp Replacement

1. Place the transmission in PARK.

2. Rotate the turn signal socket

counter-clockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the

socket.

5. Install the new lamp. Test the lamp for proper operation.

6. Reinstall all components in reverse order.

Fuse Replacement

Fuse Panel

Fuses

5or61520 20

If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a compartment.

1. Remove the front box/rack.

2. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage.

3. Reinstall the front box/rack.

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 120 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

Plug Condition Torque Specification

New Spark Plug 12-15 N-m

Previously Installed Spark Plug 23-27 N-m

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color . See page 99.

Normal Spark Plug

The normal insulator tip is tan or brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor adjustments.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect carburetor adjustments.

Polaris ATV Sportsman Forest 500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual