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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 1-800-342- 3764 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 recreational 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.com. Have your accessories and clothing delivered right to your door!
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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 inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
Printed in U.S.A.
2007 Sportsman 500 X2/Sportsman 800 X2 Owner’s Manual P/N 9920632
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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
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4
KNOW YOUR VEHICLE
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.
Engine Serial Number
####
VIN
Key Number
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
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SAFETY
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.
Age 16 Warning
+ +
Discretionary
Warning
•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.
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SAFETY
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:
+
General
Warning
•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.
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SAFETY
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:
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Passenger Safety
Warning
•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
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SAFETY
Safety Decals and Locations
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.
Tire Pressure/Load
Warning
+
Read Owner's Manual for more detailed loading information.
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SAFETY
Safety Decals and Locations
Rack |
Box |
Warning |
Warning |
+ +
+
Clutch Cover
Warning
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.
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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)
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SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.
Helmet
|
Eye Protection |
|
Long |
Gloves |
|
Sleeves |
||
|
Long Pants
Boots
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.
E4
051039
0006.31
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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.
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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.
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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 RiderCoursesm. You were also provided with 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 RiderCoursesm by calling ATV 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.
We 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.
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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.
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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 RiderCoursesm. Contact ATV 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 ATV 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 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.
•Always avoid operating an ATV on paved surfaces, including sidewalks, driveways, parking lots, and streets.
•Never operate an ATV on a public street, road or highway, including a dirt or gravel road.
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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 ATV.
•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.
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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.
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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.
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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 any 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) mowers, 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.
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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 RiderCoursesm offered by 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.
WARNING
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.
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SAFETY
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.
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.
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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.
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SAFETY
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.
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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.
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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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