Polaris Sporstman X2 800 EFI, Sportsman 500 X2, Sportsman 9920632, Sportsman 800 X2 User Manual

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-3423764 for assistance.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide 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 We believe Polaris sets a standard of excellence for all utility and recre-

ational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your 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.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www .purepolaris.co m. Have your accessories and clothing delivered right to your door!

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2006 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.

Printed in U.S.A. 2007 Sportsman 500 X2/Sportsman 800 X2 Owner’s Manual P/N 9920632

TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . 38

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Emission Control Systems . . . . . . . . . . . . . . . 84

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 139

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 143

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 144

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 154

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

KNOW YOUR VEHICLE

####

VIN

Engine Serial Number

Key Number

As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

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

Discretionary Warning

Age 16 Warning

Safety Decals and Locations

Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV.

If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

Discretionary Warning

WARNING

• Never operate this ATV on HILLS steeper than 15 degrees 15°. To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.

• Never operate this vehicle in TURF mode on irregular terrain, including hills and obstacles.

• REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of control, never activate override button with open throttle.

• When this ATV is not in operation, or unattended, place shift in the park position.

Age 16 Warning

WARNING Operating this ATV if you are under the age of 16 increases your chance of

severe injury or death. NEVER operate this ATV if you are under age 16.

SAFETY

General

Warning

Safety Decals and Locations

General Warning

WARNING Improper ATV use can result in SEVERE

INJURY or DEATH

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGER

NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN ONE

PASSENGER NEVER USE WITH DRUGS OR

ALCOHOL NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills, your passenger’s skills, or the conditions

• on public roads - a collision can occur with another vehicle

• with more than one passenger - passengers affect balance and steering and increase risk of losing control

• with a passenger under the age of 12

THE OPERATOR MUST ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

• reduce speed and use extra caution at all times when carrying a passenger have passenger dismount when conditions require

• make sure passenger reads and understands this label and passenger safety label

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A

REPLACEMENT.

SAFETY

Passenger Safety

Warning

Safety Decals and Locations

Passenger Safety Warning

WARNING PASSENGER SAFETY to reduce the risk

of SEVERE INJURY or DEATH

NEVER CARRY A PASSENGER UNDER AGE 12

NEVER CARRY MORE THAN ONE PASSENGER

NEVER RIDE AFTER USING DRUGS OR ALCOHOL

NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds.

THE PASSENGER MUST ALWAYS:

• use an approved helmet and protective gear

• securely grasp hand holds and plant feet firmly on footrests

• tell operator to slow down or stop if uncomfortable - get off and walk if conditions require

Safety Decals and Locations

Tire Pressure/Load

Warning

Tire Pressure/Load Warning

WARNING IMPROPER TIRE PRESSURE OR

OVERLOADING can cause loss of control resulting in SEVERE INJURY

OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, OPERATOR, PASSENGER AND CARGO IS 1500 LBS. (680 kg).

Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible in box, and firmly secured to the rack. For stability on rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack or box.

Read Owner's Manual for more detailed loading information.

SAFETY

Clutch Cover

Warning

Rack

Warning

Box

Warning

Safety Decals and Locations

Rack Warning, Front

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 combined Front Rack and Container Load: 90 lbs. (41 kg)

Clutch Cover Warning

WARNING NO STEP

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.

SAFETY

Safety Decals and Locations

Reverse Override Warning

WARNING 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.

Box Warning

WARNING Remove flammable material

containers from box before filling.

WARNING Passengers can be thrown off. This can cause serious

injury or death. Never carry passengers in cargo box. Maximum Box Load - 400 lbs. (181 kg)

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, 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

Rider Safety

WARNING

Failure to follow the warnings contained in this manual can result in severe injury or death.

A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand your owner's manual and all warnings before operating a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV.

SAFETY

Rider Safety

Safety Training

ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV

RiderCoursesm available to you and your eligible family members. This

training is included in the purchase price of your ATV. Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV, you can take the ATV

RiderCourse

by calling A TV Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.

W e strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

. You were also provided with

SAFETY

Rider Safety

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, on your vehicle or in this manual, alerts you to the potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE

A note will alert you to important information or instructions.

SAFETY

Rider Safety

WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual.

• Read this manual and all labels carefully, and follow the operating

procedures described.

• Never operate an ATV without proper instruction. Take a training

course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCoursesm.

• Never allow anyone under 16 years of age to operate this ATV.

• Never allow anyone under 12 years of age to ride as a passenger on

this 2-up ATV. Make sure any passenger is tall enough to comfortably and safely reach the handgrips and footrests.

• Never secure a passenger to the vehicle or to the operator with a belt,

rope or similar device.

• Never carry more than one passenger on this 2-up ATV.

• Always make sure the passenger seat lock-out is functioning properly

before carrying a passenger.

• Never permit a guest to operate the A TV unless the guest has read this

manual and all product labels and has completed a certified safety training course.

• Always keep both hands on the handlebars and both feet on the foot-

rests of the ATV during operation. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

• Always avoid operating an ATV on paved surfaces, including side-

walks, driveways, parking lots, and streets.

• Never operate an ATV on a public street, road or highway , including a

dirt or gravel road.

. Contact ATV

SAFETY

Rider Safety

• Never operate an ATV without wearing an approved helmet that fits properly . Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. A passenger's helmet should have a rigid chin guard.

• Never consume alcohol or drugs before or while operating an AT V.

• Never operate at excessive speeds. Travel at speeds appropriate for your skills, your passenger's skills, and operating conditions.

• Never attempt jumps or other stunts.

• Always inspect your ATV before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner's manual.

• Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain conditions.

• Never operate on excessively rough, slippery, or loose terrain.

• Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.

• Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident.

• Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

• Never operate this ATV in TURF mode while operating on a hill or other irregular terrain. See page 47.

• Always follow proper procedures for climbing hills. Check the terrain carefully before ascending a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight uphill. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed. Switch the AWD switch out of TURF mode and into AWD mode when ascending a hill.

SAFETY

Rider Safety

• Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill. Shift your weight uphill. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Drive straight downhill.

• Always follow proper procedures for crossing the side of a hill. Do

not cross a hillside with a passenger on board. Avoid hills with excessively slippery or loose surfaces. Shift your weight uphill. Never attempt to turn the ATV around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible.

• Always use proper procedures if you stall or roll backwards while

climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual.

• Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

• Always be careful of skidding or sliding. On slippery surfaces like

ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

• Avoid operating the ATV through deep or fast-flowing water. If it's

unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

• Wet brakes may have reduced stopping ability. Test the brakes after

leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.

SAFETY

Rider Safety

• Always check for obstacles or people behind the ATV before operating in reverse. Be aware that a passenger can obstruct your view. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles.

• Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure.

• Never modify an ATV through improper installation or use of accessories.

• Never exceed the stated load capacity for your ATV. 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.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-

3764.

SAFETY

Rider Safety

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your Polaris ATV is terminated if an y equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited to) mow-

ers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the

operator does not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE HAZARD Beginning and inexperienced operators should

complete the ATV RiderCourse Polaris through the SVIA. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual.

For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a child under the minimum age

recommendation operates this ATV or rides as a passenger. Even though a child may be within the recommended age group for operating

some ATVs, he/she may not have the skills, abilities, or judgment needed to operate or ride on this ATV safely and could be susceptible to accident or injury.

HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. Never allow

anyone under 12 years of age to ride as a passenger on this 2-up ATV.

offered by

WARNING

Rider Safety

WARNING

POTENTIAL HAZARD Operating with more than one passenger. WHAT CAN HAPPEN Passengers affect balance and steering and

increase the risk of losing control, which can result in severe injury or death.

HOW TO AVOID THE HAZARD Never operate the 2-up ATV with more than

one passenger.

WARNING

POTENTIAL HAZARD Carrying a passenger in the cargo box. WHAT CAN HAPPEN A passenger riding in the cargo box could fall

from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death.

HOW TO AVOID THE HAZARD Never allow a passenger to ride in the cargo

box.

SAFETY

WARNING

POTENTIAL HAZARD Operating an ATV on paved surfaces, including

sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use.

Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control, accident, and/or injury.

HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement. If it's

unavoidable, travel slowly and avoid sudden turns or stops.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating this ATV on public streets,

roads or highways. WHAT CAN HAPPEN The ATV could collide with another

vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public

street, road or highway, including dirt and gravel roads. In many states it's illegal to operate ATVs on public streets, roads and highways.

WARNING

POTENTIAL HAZARD Riding an ATV without wearing an

approved helmet, eye protection and protective clothing.

WHAT CAN HAPPEN Riding an ATV without an approved

helmet increases the risk of a severe head injury or death in the event of an accident.

Riding without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident.

HOW TO AVOID THE HAZARD Always be sure operator and passenger wear an approved helmet that fits

properly. A passenger's helmet should have a rigid chin guard. Always be sure operator and passenger wear eye protection (goggles or face

shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.

Rider Safety

WARNING

POTENTIAL HAZARD Operating the ATV after consuming alcohol or

drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could

seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.

HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV.

WARNING

POTENTIAL HAZARD Operating the ATV at excessive

speeds. WHAT CAN HAPPEN Excessive speed increases the

operator's chance of losing control of the ATV, which can result in an accident causing severe injury or death.

HOW TO AVOID THE HAZARD Never operate at excessive

speeds. Travel at speeds appropriate for your skills, your passenger's skills, and operating conditions.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of

an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt jumps or other stunts.

Avoid exhibition driving.

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of

an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to

make sure it's in safe operating condition. Always follow the inspection and maintenance

procedures and schedules described in the owner's manual.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Removing hands from the handlebars or

feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can

reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.

If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury.

HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of

the ATV during operation. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

WARNING

POTENTIAL HAZARD Failure to use extra caution when

operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden

rocks, bumps, or holes that could cause loss of control or overturn.

HOW TO AVOID THE HAZARD Travel slowly and use extra caution

when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

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