Polaris Sportsman 9921837 User Manual
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)
• Quadricycles/Tractors
• RANGER utility vehicles
• Victory motorcycles
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at
www.polarisindustries.com.
1
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2008 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.
2009 Sportsman 500 EFI Tractor Owner’s Manual
P/N 9921837
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Emission Control Systems . . . . . . . . . . . . . . . 60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 116
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 118
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 119
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 126
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
INTRODUCTION
WARNING
Failure to follow the warnings in this manual can result in serious injury or death.
A Polaris Tractor is not a toy and can be hazardous to operate. A collision or
rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a Polaris Tractor.
• Never operate this vehicle without proper instruction. Take a training course.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Tractor/
trailer combination on public roads is prohibited. See your Polaris dealer
about configuring the vehicle to be certified to tow a trailer on-road.
5
INTRODUCTION
####
VIN
Engine Serial Number
Key Number
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
6
SAFETY
Safety Training
When you purchased your new Tractor, 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 Tractor from a party other than a Polaris
dealer, please request free safety training from any authorized Polaris
dealer.
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, 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.
Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.
Equipment Modifications
The warranty on your Polaris Tractor may be terminated if any equipment has been added, or if any modifications have been made, that
increase speed or power. The addition of certain accessories, including
(but not limited to) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only Polaris-approved accessories. Know
their function and effect on the vehicle.
7
SAFETY
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
8
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide the
best protection.
9
SAFETY
WARNING
<
1
6
1
6
1
6
Rider Safety
Serious injury or death can result if you do not follow the instructions and
procedures listed here and throughout this manual.
Read and understand all warnings, cautions and
operating procedures in this manual and on the safety
labels before operating the Tractor.
Never operate a Tractor without proper instruction.
Take a training course. Beginners should receive
training from a certified instructor. Contact an
authorized Polaris Tractor dealer or visit the Polaris
web site at www.polarisindustries.com.
Never permit others to operate the Tractor unless
they have read and understand this manual and all
product labels, and have completed a certified safety training course.
Never allow anyone under 16 years of age to operate
this vehicle.
Gasoline is highly flammable and explosive under certain conditions.
• Use extreme caution whenever handling gasoline.
• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.
• Never fill a fuel container while it's on the vehicle. Static electricity between
the rack and container could cause a spark.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
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.
10
Rider Safety
Never carry a passenger on this vehicle.
Always wear an approved helmet that fits
properly. Wear eye protection (goggles or face
shield), gloves, boots, long sleeves and long
pants.
Never consume alcohol or drugs before or
while operating a Tractor.
SAFETY
Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.
11
SAFETY
Rider Safety
Always inspect your Tractor before each
use to verify that it's in safe operating
condition. Follow the inspection and
maintenance procedures outlined in this
manual. See page 41.
Keep both hands on the handlebars. Keep
both feet on the footrests.
Always travel slowly when operating on
unfamiliar terrain. Use extra caution.
Always follow the procedures outlined in
this manual for turning. See page 45.
Never turn sharply at excessive speeds,
which can lead to vehicle overturn.
If a Tractor has been involved in an accident, always have an authorized Polaris
dealer inspect the entire vehicle for possible damage, including (but not limited
to) brake, throttle and steering systems.
12
Rider Safety
Never attempt jumps or other stunts.
Always follow the procedures outlined in this
manual for driving on hills. See page 46.
Never operate on hills too steep for the
Tractor or for your abilities. Practice on
smaller hills before attempting larger hills.
Avoid climbing hills steeper than 25°.
Always move the 4X4 switch to ADC 4X4
before ascending or descending a hill.
Always follow the procedures outlined in this
manual for driving downhill and for braking
on hills. See page 49.
SAFETY
Always follow the procedures outlined in this
manual for crossing the side of a hill. See
page 48.
Never attempt to turn the Tractor around on
any hill until you've mastered (on level
ground) the turning technique outlined in this
manual.
Use the front hitch for vehicle recovery or
towing only. Always remove the front hitch
before operating in forward gear. See page
26.
13
SAFETY
Rider 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 50.
Always follow the procedures outlined in this manual for operating over
obstacles. See page 55.
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 54.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water. See page
52.
14
SAFETY
Rider Safety
Always follow the procedures outlined in this manual for driving in reverse. See
page 56.
Always use the size and type of tires
specified for your vehicle. Maintain
the proper tire pressure.
Never modify a Tractor through
improper installation or use of
accessories.
Never exceed the stated load
capacity for your vehicle. Cargo must
be properly distributed and securely
attached. Reduce speed and follow
the instructions in this manual for
carrying cargo or towing. Allow a
greater distance for braking.
15
SAFETY
Rider Safety
Never operate the Tractor on a frozen body of water.
Operating on paved surfaces may
affect the handling and control of the
Tractor and could result in loss of
control. Avoid sudden turns or swift
movement of the handlebars.
Always remove the ignition key when
the vehicle is not in use to prevent
unauthorized use or accidental
starting.
Always unlock the steering before starting the engine. See page 26.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about Tractor safety,
contact an authorized Polaris Tractor dealer or visit the
Polaris web site at www.polarisindustries.com.
16
SAFETY
+
General
Alert
+
Hill Operation
and Hitch Alert
+
Age 16 Alert
<
1
6
1
6
1
6
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If a label
becomes illegible or comes off, contact your Polaris dealer to purchase a
replacement. Replacement safety labels are provided by Polaris at no
charge. The part number is printed on the label.
The following pages repeat the information found on each label.
General Alert
(Multi-Lingual)
Before you operate this
vehicle, read the
owner’s manual.
7173025
Hill Operation/Hitch Alert
• Never operate this vehicle on HILLS steeper than 25 degrees 25°.
• To prevent flip-over on hilly terrain, when going up or down, use throttle and
brakes gradually.
7175814
17
SAFETY
+
Reverse Override
Alert
+
“No Passenger”
Warning
+
+
Rack
Warning
Rack
Warning
Tire Pressure/
Load Alert
+
+
Clutch
Cover Alert
Safety Labels and Locations
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (kPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY 420 LBS. (191 kg)
INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES.
Read Owner's Manual for more detailed loading information.
7174877
Reverse Override Alert/4X4 (AWD) Switch
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 4X4 (AWD). See Owner's Manual.
4X4 (AWD) SWITCH
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage. See your Owner’s Manual.
18
7175106
SAFETY
Safety Labels and Locations
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in
SEVERE INJURY or DEATH.
7175378
Clutch Cover Alert
NO STEP
7173030
Rack Warning
WARNING
• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
• Max. Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
7172572
19
FEATURES AND CONTROLS
Horn Switch
Hazard
Switch
Main Key Switch
Engine Stop Switch
Headlight
Switch
4X4 Switch
Turn Signal Switch
Mode/Reverse
Override Switch
Master Light
Switch
Switches
Master Light Switch
The master light switch must be in the ON position to allow operation of
the headlights, parking lights and taillights.
Mode/Reverse Override Switch
Press the switch to toggle through the speedometer display modes
(except in reverse). See page 31.
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 4X4 in
reverse, if the 4X4 switch is on.
Activating the override switch while the throttle is open can cause loss of control.
Do not activate the override switch while the throttle is open.
20
FEATURES AND CONTROLS
Engine
Stop Switch
Light
Switch
Switches
Main Key Switch
End all electrical power to the vehicle.
The LIGHTS ON position turns the headlights
on. The master light switch must be on and the
engine stop switch must be in the RUN position.
Start the engine. The headlights are not on in
this position.
After starting the engine, release the key switch to the PARKING
LIGHTS ON position. The headlights and taillights are on in this
position.
Do not attach a large key fob or key ring to the main switch. It may contact the
gas tank cap when turning, causing an interruption to the electrical system and
an unexpected engine shut-down during operation. This could result in serious
injury or death.
Engine Stop Switch
The engine will not start or run when
the switch is in the OFF position.
OFF (STOP)
RUN
Light Switch (High/Low Beam)
Use the light switch to change the
headlights from high beam to low
beam. The master light switch must
be on to operate the headlights.
High Beam
Low Beam
21
FEATURES AND CONTROLS
4X4 Switch
Tu r n
Indicators
Hazard Warning
Switch
Horn Switch
Turn Signal
Switch
Switches
4X4 Switch
Use the 4X4 switch to engage
ADC 4X4, 4X4 or 2X4. See
page 28.
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.
Turn Signal Switch
Push the toggle switch
either left or right to
activate the corresponding
turn signal light. The
indicator on the pod will
also flash. Return the
toggle to the center
position and push it
inward to end the signal.
Horn Switch
Press the horn switch to sound the horn.
22
FEATURES AND CONTROLS
Electronic Throttle Control
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving the Tractor.
Throttle Lever
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Check the lever for
proper operation before starting the engine. Check occasionally during
operation.
Do not start or operate a Tractor with sticking or improperly operating throttle
controls. Contact your dealer for repair if throttle problems arise.
Press the throttle lever to increase
engine speed and vehicle movement.
Release the lever to reduce engine
speed and vehicle movement.
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 this safety feature or replace it with other
throttle mechanisms.
23
FEATURES AND CONTROLS
Foot Brake
Brakes
Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause the
rear wheels to skid and result in loss of control. Read this owner's manual and
understand the operation of all brake systems on this vehicle. Always use
caution whenever applying the brakes.
Foot Brake
The all-wheel foot brake is located on the
right footrest. The foot brake operates both
front and rear brakes. Press the brake pedal
down with your foot to apply the all-wheel
brakes. If the rear wheels begin to skid or
slide while using the foot brake, reduce
brake pressure.
Hand Brake Lever
The hand brake operates both front and rear
brakes. Squeeze the brake lever toward the
handlebar to apply the all-wheel brakes. If
the rear wheels begin to skid or slide while
using the brake, reduce lever pressure.
Parking Brake
1. Place the transmission in PARK.
2. Squeeze the brake lever toward the han-
dlebar. Push the parking brake lock forward to engage the lock. Release the
brake lever.
3. To release the parking brake lock,
squeeze and release the brake lever.
Operating the vehicle while the parking brake is engaged could result in an
accident and serious injury or death. Always release the parking brake lock
before operating.
24
FEATURES AND CONTROLS
Load Adjuster
Measure Preload
(shown with seat removed)
Height Adjustment Slots
Backrest Knobs
Seat
Seat Load Adjustment
Adjust the seat spring for the comfort
of a lighter or heavier operator. Reach
under the rear rack to access the
adjuster. Tighten the spring for heavier
riders. Loosen the spring for lighter riders.
Use the following table to determine
the best preload measurement for rider
weight. Measure preload between the
adjuster plate and the lower spring
retainer.
Rider Weight
Up to 39 kg 0 mm
39-94 kg 0-32 mm
Over 94 kg 32-64 mm
Driver's seat, type Seat One:
e11*78/764*2006/96*2056*00
Seat Removal
Lift the latch bar at the rear of the seat to
release the latch. Tilt the seat slightly rearward to disengage the seat tabs from the
rear seat base slots. Remove the seat.
Make sure the seat is securely installed
before operating.
Seat Height Adjustment
To raise or lower the seat, remove the seat
and reposition the seat tabs in one of the
rear seat base slots. Make sure the seat is
securely installed before operating.
Backrest Adjustment
Loosen the backrest knobs on each side of
the backrest mount and slide the backrest
forward or rearward to the desired position. Tighten the knobs securely.
Preload
Measurement
25
FEATURES AND CONTROLS
Steering Lock
Lock the steering to prevent unauthorized use or theft of the vehicle.
The handlebars are locked in the fully turned position when the steering is
locked. Always unlock the steering before starting the engine.
1. Turn the handlebars to the full right
position. The handlebars may also be
locked in the full left position.
2. Insert the steering lock key and turn it
clockwise. Remove the key.
3. Place the steering lock keys in a safe
place. The lock must be replaced if the
keys are lost.
4. Reverse the procedure to unlock the steering.
Hitches
See page 116 for hitch weight capacities.
Front Hitch
Use the front hitch for vehicle recovery or towing only. Do not use the
front hitch for any other purpose. Always remove the front hitch before
operating in forward gear.
Rear Hitch
Hitch specifications may differ from vehicle capacity specifications. Do
not exceed the hitch and towing capacities specified for this vehicle. See
page 116.
Use the rear hitch for towing a trailer. See pages 57-59 for procedures.
Rear Hitch Specifications
Material 1021 M Steel
Fasteners 1008K Steel (Main Pin and Receiver Pin)
Weld Length and Positions 3 mm fillet, both sides, all around
Maximum Vertical Load 75 kg (on coupling point)
Maximum Towable Mass 750 kg
Approval # e11*89/173*2006/26*2073*xx
26
FEATURES AND CONTROLS
Step 2Step 1 Step 3
Gear
Selector
Fuel Tank
Cap
Hitches
Hitch Installation/Removal
1. Release the wire lock from the 12.7 mm pin and remove the pin.
2. Install the hitch to the receiver.
3. Install the 12.7 mm pin through the bore of both the receiver and the
hitch. Secure the wire lock. Make sure the hitch assembly is secure
at that the wire lock is properly engaged over the pin.
4. To remove the hitch, release the wire lock, remove the hitch, rein-
stall the pin to the receiver and secure the wire lock.
Automatic 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
Whenever the vehicle is left unattended, always place the transmission
in PARK. The transmission is locked when it’s in PARK.
NOTICE: Shifting gears with the engine speed above idle or while the vehicle is
moving can cause transmission damage. Stop the vehicle, release
the throttle and move the shift lever to the desired gear. See your
dealer if you experience any shifting problems.
Fuel Tank Cap
Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded
or unleaded gasoline with a minimum pump octane of 87. Do not use E-
85 fuel.
27
FEATURES AND CONTROLS
All Wheel Drive (4X4) System
The All Wheel Drive system is
controlled by the 4X4 switch.
ADC 4X4
When the switch is on ADC
4X4, the ADC system allows
engine braking to all four
wheels when the vehicle
descends a hill or incline.
Always move the 4X4 switch to
ADC 4X4 before ascending or
descending a hill. See page 30.
4X4
When the switch is on 4X4,
the vehicle is in 4X4, and the
4X4 indicator light in the
instrument cluster will be on.
When in 4X4, the demand
drive unit will automatically
engage any time the rear wheels lose traction. When the rear wheels
regain traction, the demand drive unit will automatically disengage.
There is no limit to the length of time the vehicle may remain in 4X4.
The override switch allows activation of 4X4 in reverse if the 4X4
switch is on. See page 20.
2X4
When the switch is on 2X4,
the vehicle is in two-wheel
drive at all times.
28
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