Polaris Sportsman 9922551 User Manual
Pantone 426c
Sportsman 500 Touring
International
2010
Owner's Manual
for Maintenance and Safety
Read this manual carefully.
It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
PASSENGER
UNDER
12
Pantone 426c
GB
D
E
F
I
FI
P
S
Before you operate or ride this vehicle, read the
owner’s manual.
Lesen Sie die Bedienungsanleitung, bevor Sie
dieses Fahrzeug bedienen oder fahren.
Antes de operar o conducir este vehículo, lea el
Manual del propietario.
Lire le Manuel d’utilisation avant d’utiliser ou de
conduire ce véhicule.
Prima di usare o guidare il veícolo, leggere il
Manuale di istruzioni.
Lue aina käyttöohjekirja ennen tämän ajoneuvon
käyttöä tai ajamista.
Antes de utilizar ou andar neste veículo, leia o
Manual do proprietário.
Innan du hanterar eller kör detta fordon, läs
Handboken.
For your nearest Polaris dealer,
visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
U.S.A.
Part No. 9922551 Rev 01
Printed in U.S.A.
The text is printed on 100% recycled
with 40% post-consumer waste (PCW).
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
• 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.
®
utility vehicles
®
®
1
POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris
Industries Inc.
Copyright 2009 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.
2010 SPORTSMAN 500 Touring International Owner’s Manual
P/N 9922551
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Emission Control Systems . . . . . . . . . . . . . . . 60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 118
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 120
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121
Declaration of Conformity . . . . . . . . . . . . . . . 125
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 130
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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.
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. See your Polaris
dealer about configuring the vehicle to be certified to tow a trailer onroad.
Equipment Modifications
The warranty on your Polaris vehicle may be terminated if any equipment has been added, or if any modifications have been made, that
increase speed or power. The addition of certain accessories, including
(but not limited to) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only Polaris-approved accessories. Know
their function and effect on the vehicle.
5
INTRODUCTION
####
VIN
Engine Serial Number
Key Number
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
6
SAFETY
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Equipment Modifications
We strongly recommend that consumers do not install on a Polaris vehicle any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.
The warranty on your Polaris vehicle 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.
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.
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
Rider Safety
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 allow anyone under 12 years
of age to ride as a passenger on this
2-up vehicle.
Never carry more than one
passenger on this 2-up vehicle.
10
Rider 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.
SAFETY
Never attempt jumps or other stunts.
Always inspect your 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 38.
11
SAFETY
Rider Safety
Keep both hands on the handlebars.
Keep both feet on the footrests.
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 travel slowly when operating
on unfamiliar terrain. Use extra
caution.
Use caution when operating on
rough, slippery or loose terrain.
Always follow the procedures
outlined in this manual for turning.
See page 43.
Never turn sharply at excessive
speeds, which can lead to vehicle
overturn.
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.
12
Rider Safety
>15°
Always follow the procedures
outlined in this manual for driving on
hills. See page 46. 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 15°.
Always follow the procedures
outlined in this manual for driving
downhill and for braking on hills. See
page 49.
Always follow the procedures
outlined in this manual for crossing
the side of a hill. See page 48.
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
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.
13
SAFETY
Rider Safety
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.
Always follow the procedures
outlined in this manual for driving in
reverse. See page 57.
14
Rider Safety
Always use the size and type of tires
specified for your vehicle. Maintain
the proper tire pressure.
Never modify the 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
Never operate the vehicle on a
frozen body of water.
15
SAFETY
Rider Safety
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 28.
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• 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.
• Turn the fuel valve off whenever the vehicle is stored or parked.
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.
16
SAFETY
+
General
Alert
+
Hill
Operation
Alert
+
Age 16
Alert
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions on each decal carefully. If a 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.
The following pages repeat the information found on each decal.
General Alert
(Multi-Lingual)
Before you operate or
ride this vehicle, read
the owner’s manual.
Hill Operation Alert
• Never operate this vehicle on HILLS
steeper than 15 degrees 15°.
• To prevent flip-over on hilly terrain,
when going up or down, use throttle
and brakes gradually.
17
SAFETY
+
+
Front Rack
Warning
Tire Pressure/
Load Alert
+
+
Clutch
Cover Alert
Rear Rack
Warning
+
Reverse Override
Alert
Safety Decals and Locations
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY 568 LBS. (258 kg)
INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND
ACCESSORIES.
Read Owner's Manual for more detailed loading information.
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 4X4. See Owner's Manual.
18
SAFETY
Safety Decals and Locations
Rack Warning, Front and Rear
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. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
Clutch Cover Alert
NO STEP
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
Choke
Switches
Mode/Reverse Override Switch
Press the switch to toggle through the speedometer display modes
(except in reverse). See page 32.
To gain additional power while operating in reverse, press the override
switch before opening the throttle. This will cancel the reverse speed
limit function.
Tip: 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,
resulting in severe injury or death. 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.
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.
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
RUN
Light 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
21
FEATURES AND CONTROLS
4X4 Switch
Tu r n
Indicators
Hazard Warning
Switch
Switches
4X4 Switch
Use the 4X4 switch to engage
4X4 or 2X4. See page 30.
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.
22
FEATURES AND CONTROLS
Horn 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 and push it
inward to end the signal.
Horn Switch
Press the horn switch to sound the horn.
23
FEATURES AND CONTROLS
Electronic Throttle Control
Throttle Lever
Press the throttle lever to increase
engine speed and vehicle movement. Release the lever to reduce
engine speed and vehicle movement.
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 the vehicle with sticking or improperly operating throttle
controls. Contact your dealer for repair if throttle problems arise.
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving the vehicle.
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.
24
FEATURES AND CONTROLS
Foot Brake
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.
25
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. Release the brake
lever.
4. 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.
26
FEATURES AND CONTROLS
Recoil
Starter
Handle
OFF
ON
Recoil Starter (if equipped)
If the battery is too weak to start the
engine, use the recoil starter. Follow
the starting procedures on page 39,
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.
If the starter rope handle is not seated properly, water may enter the recoil
housing and damage components.
Choke
The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 39 for correct choke and throttle settings during starting.
Fuel Valve
The fuel valve is located under the
front storage box cover.
OFF: For vehicle storage and when
transporting.
ON: For normal operation.
27
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