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1
WELCOME
Thank you for choosing Polaris, and welcome to our world-wide
family of Polaris enthusiasts. Polaris proudly produces an exciting line
of recreational products, including snowmobiles, all-terrain vehicles,
personal watercraft, utility vehicles, and Victory motorcycles.
We believe Polaris sets the standard of excellence for all recreational
vehicles manufactured in the world today. Many years of experience in
engineering, design, and development have gone into making your
Polaris vehicle the finest machine we’ve ever produced.
Follow the instructions and recommendations in this Owner’s Manual
for safe and enjoyable operation of your vehicle. Your Owner’s Manual
contains instructions for minor maintenance. Major repairs are covered
in the Polaris Service Manual and should be performed by a Factory
Certified MSD (Master Service Dealer) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
complete satisfaction. Return to your dealership for all of your service
needs during, and after, the warranty period.
Polaris also takes great pride in our PAA (Parts Apparel and
Accessories) which are available on our online store
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
Polaris and Polaris The Way Out are registered trademarks of Polaris
Industries Inc.
Copyright 2002
Polaris Industries Inc.
All Rights ReservedPrinted in the U.S.A.
2
WARNING
Failure to follow the warnings contained in this manual can result
in severe injury or death.
A Polaris ATV Pro 500 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 Pro 500.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
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.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. 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 from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
NOTE: Illustrations used in this manual are for general representation
only. Your model may differ.
The frame vehicle identification number (VIN) (1) and engine serial
number (2) are important for model identification when registering
your vehicle, when obtaining insurance, and when ordering
replacement parts. If your vehicle is stolen, these numbers are essential
to its recovery and identification.
NOTE: Record your vehicle’s ID numbers in the spaces provided.
Remove the spare key and store it in a safe place. Your key can be
duplicated only by mating a Polaris key blank with an existing key.
NOTE: If both keys are lost, see your dealer for ignition switch
replacement.
Shift TypeSide Lever (High, Low, Neutral, Reverse,
Park)
Gear Reduction - Low7.5/1
Gear Reduction - Reverse5.11/1
Gear Reduction - High2.89/1
Drive Ratio - Front:3.82/1
Drive Ratio - Final3.10/1
Tire Size - Front25 x 8 - 12
Tire Size - Rear25 x 11 - 12
Front BrakeHydraulic Disc
Rear BrakeHydraulic
Parking BrakeHydraulic lock, all wheel
Headlight (watts)1 - Single Beam on Handlebar (50)
2 - Single Beam on Grill (27)
Taillights (watts)8.26
Brake Light (watts)26.9
Instrument ClusterLCD
Clutching and Jetting Charts
AltitudeAMBIENT
TEMPERATURE
Meters
(Feet)
AltitudeShift
Meters
(Feet)
(6000-12000)
8
0-1800
(0-6000)
1800-3700
(6000-12000)
0-1800
(0-6000)
1800-3700
Weight
20-56
PN 5631315
20-54
PN 5631214
EBS models require no helix / spring adjustment
Below 40° F
Below 5° C
175162.5
150140
Drive Clutch
Spring
Blue/Green
PN 7041157
Blue/Green
PN 7041157
Driven
Clutch
Spring
White/Yellow
PN 7041635
White/Yellow
PN 7041635
+40°Fand above
+5°C to & above
Helix*
EBS
PN 5132751
EBS
PN 5132751
SAFETY
Understanding Warnings
The following two pages identify signal words and symbols that appear
in this manual. 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 personal 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 personal 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.
9
SAFETY
Key Safety Issues
Protect Your Sport
Know all local, state/province riding laws;
Respect your vehicle;
Respect the environment; and
You will gain the respect of others.
We also advise you to strictly follow the recommended maintenance
program as outlined. This preventive maintenance program is designed
to ensure that all critical components on this ATV are thoroughly
inspected at various intervals.
All information in this manual is based upon the latest product data and
specifications available at the time of printing. Polaris Industries Inc.
reserves the right to make product changes and improvements which
may affect illustrations or explanations.
No part of this manual shall be reproduced or used without the written
permission of Polaris Industries Inc.
Illustrations included in this manual are general representations of
parts having a similar function. Your model may differ.
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO
OPERATE. An ATV handles differently from other vehicles
including motorcycles and cars. A collision or rollover can occur
quickly, even during routine maneuvers such as turning and driving on
hills or over obstacles, if you fail to take proper precautions.
10
SAFETY
Key Safety Issues
SERIOUS INJURY OR DEATH can result if you do not
follow these instructions:
Read this manual and all labels carefully and follow the operating
procedures described.
Never operate an ATV without proper instruction. Take a training
course. Beginners should receive training from a certified instruc-
tor. Contact an authorized Polaris ATV dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
Never allow anyone under 16 years of age to operate this ATV.
Never permit a guest to operate this ATV unless the guest has read
this manual and all product labels, and has completed a certified
training course.
Always avoid operating an ATV on any paved surfaces, including
sidewalks, driveways, parking lots and streets.
Never operate an ATV on any public street, road or highway, even a
dirt or gravel one.
Never operate an ATV without wearing an approved helmet that fits
properly. You should also wear eye protection (goggles or face
shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
Never consume alcohol or drugs before or while operating this
AT V.
Never operate at excessive speeds. Always travel at a speed which
is proper for the terrain, visibility and operating conditions, and
your experience.
Never attempt wheelies, jumps or other stunts.
Always inspect your ATV each time you use it to make sure it is in
safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the
footrests of the ATV during operation.
Always go slowly and be extra careful when operating on unfamil-
iar terrain. Always be alert to changing terrain conditions when
operating the ATV.
Never operate on excessively rough, slippery or loose terrain.
Always follow proper procedures for turning as described in this
manual. Practice turning at low speeds before attempting to turn at
faster speeds. Do not turn at excessive speed.
Always have the ATV checked by an authorized Polaris dealer if it
has been involved in an accident.
11
SAFETY
Key Safety Issues
Never operate the ATV on hills too steep for the ATV or for your
abilities. Practice on smaller hills before attempting larger hills.
Always follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before you start up any
hill. Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward. Never open the throttle suddenly or
make sudden gear changes. Never go over the top of any hill at
high speed.
Always follow proper procedures for going down hills and for brak-
ing on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward.
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.
Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as
described in this manual. Avoid hills with excessively slippery or
loose surfaces. Shift your weight to the uphill side of the ATV.
Never attempt to turn the ATV around on any hill until you have
mastered the turning technique described in this manual on level
ground. Avoid crossing the side of a steep hill if possible.
Always use proper procedures if you stall or roll backwards when
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. Dismount on the
uphill side or to either side if 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 large 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,
such as ice, go slowly and be very cautious in order to reduce the
chance of skidding or sliding out of control.
Avoid operating the ATV through deep or fast flowing water. If
you cannot avoid water which exceeds the recommended maximum depth (pg. 78), go slowly, balance your weight carefully
avoiding sudden movements, 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 your brakes
after leaving water. If necessary apply them lightly several times
to let friction dry out the pads.
12
SAFETY
Key Safety Issues
Always be sure there are no obstacles or people behind you when
you operate in reverse. When it is safe to proceed in reverse, go
slowly. Avoid turning at sharp angles in reverse.
Always use the size and type tires specified in this manual. Always
maintain proper tire pressure as described in this manual.
Never modify an ATV through improper installation or use of ac-
cessories.
Never exceed the stated load capacity for an ATV. Cargo should be
properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the
Consumer Product Safety Commission at 1-800-638-2772, or Polaris
at 1-800-342-3764.
Additional Important Information...
Due to our concern for the safety of our customers and the general
public, Polaris hereby strongly recommends and requests that
consumers not have installed on a Polaris ATV any equipment which is
intended to 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 ATV substantially
increase the risk of bodily injury. Please be aware that these
modifications may create a substantial safety hazard.
Polaris hereby informs you that the warranty on your ATV is
terminated if any such equipment has been added to the ATV or any
modifications have been made to the ATV which increase its speed or
power.
We also advise you to strictly follow the recommended maintenance
program outlined in this manual. This preventive maintenance
program is designed to ensure that all critical components on the ATV
are thoroughly inspected by your dealer at various mileage intervals.
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 ATV.
Be certain any accessories added to this ATV have been approved by
Polaris.
Familiarize yourself with their function and affect on the ATV.
13
SAFETY
Safety Decals and Locations
NOTE:
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions on each decal carefully. In the event
any decal becomes illegible or comes off, contact your Polaris dealer
for a replacement. Any safety decal needing replacement will be
provided by Polaris at no charge. The part number is printed on the
decal.
1
14
Safety Decals and Locations
WARNING
1
SAFETY
IF OWNER’S MANUAL IS MISSING, CONTACT
YOUR POLARIS DEALER FOR A REPLACEMENT.
1997, 2000
7079083
15
SAFETY
Safety Decals and Locations
3
2
16
Safety Decals and Locations
SAFETY
2
WARNING
UNDER
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.
7078253
3
WARNING
Never operate this ATV on HILLS steeper than 25 degrees
To prevent flipover on hilly terrain, when going up or down,
use throttle and brakes gradually.
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.
PARKING BRAKE may relax when used for more than 5 minutes.
When parking on grades, leave shift in forward.
25°
7079085
17
SAFETY
Safety Decals and Locations
4
18
5
6
Safety Decals and Locations
6
(on rear of seat)
WARNING
SAFETY
4
5
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, DRIVER AND CARGO IS 1200 LBS.
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, and firmly secured to
the racks. With dual racks, load distribution 1/3 front 2/3 rear is
best. 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.
Read Owner’s Manual for more detailed loading information
7079084
19
SAFETY
Safety Decals and Locations
8
(Under Seat)
7
7
Operation of this vehicle
without the air filter element
will severely damage the engine.
Clean pre-filter element often, more
frequent cleaning required
in dusty conditions. Do not
operate vehicle without pre-filter.
Operation of this vehicle without
engine breather filter(s) can cause
engine damage. Consult owner’s
manual or dealer for details.
Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle with
guard removed.
8
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.
20
ATTENTION
and adjustments are required
depending on temperature and
altitude. See your Owner’s Manual.
40 to 80 F. at 0-3000 feet
(5 to 27 C. at 0-900 meters).
WARNING
NO STEP
Specific
carburetor jetting
Factory setting:
7079902
7078689
Safety Decals and Locations
SAFETY
9
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.
AWD Models
9
9
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. Rear 180 Lbs
7079604
ALL WHEEL
DRIVE
SWITCH
Do not push switch to
engage AWD if the rear
wheels are spinning.
This may cause severe
drive shaft and clutch
damage.
See your Owner’s
Manual.
7079780
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT
INTENDED FOR USE ON PUBLIC ROADS.
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN
QUI NEST PAS DESTINE A ETRE UTILISE SUR LES
CHEMINS PUBLICS.
MANUFACTURED
BY: POLARIS IND INC.
DATE:
VIN:
PRINTED IN U.S.A.
7170021
7078472
TRAILER MAX WEIGHT:
1225 LBS. (556 KG) ON LEVEL GROUND
850 LBS. (368 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16KG)
7078261
21
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding you are doing. ATV
riding requires special protective clothing which will make you feel
more comfortable and reduce chances of injury.
1. Helmet
Your helmet is the most important
piece of protective gear for safe
riding. A helmet can prevent a
severe head injury.
Select an approved helmet which
meets or exceeds your state’s
safety standards and bears either
the Department of Transportation
(DOT) label, the American
National Standards Institute label
(ANSI z90.1), or the Snell
Memorial Foundation label.
2. Eye Protection
Do not depend on sunglasses for
proper eye protection. A pair of
goggles or helmet face shield offer
the best protection for your eyes.
They should be kept clean and be
of shatterproof design (bearing the
markings z2.1 or VESC 8).
1
2
3
5
4
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
4. Boots
The best footwear is a pair of strong over the calf type boots with
heels, such as moto-cross boots.
5. Clothing
To protect your body, long sleeves and pants should always be worn.
Riding pants with kneepads, a jersey and shoulder pads provide the
best protection.
22
Operator 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
certified training course offered by Polaris Industries Inc.
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 training course, contact an
authorized ATV dealer or call Polaris at 1-800-342-3764.
SAFETY
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not recommended for their age
can lead to severe injury or death of the child.
Even though a child may be within the age group for which some
ATVs are recommended, he or she may not have the skills,
abilities, or judgment needed to operate the ATV safely and may
be involved in a serious accident.
HOW TO AVOID THE HAZARD
No one under 16 should operate a Polaris ATV.
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this ATV.
Could cause an accident, resulting in harm to you and/or your
passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The long seat is to allow the
operator to shift position as needed during operation. It is not
for carrying passengers.
24
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV on paved surfaces, including sidewalks,
paths, parking lots, and driveways.
WHAT CAN HAPPEN
The ATV tires are designed for off-road use. Paved surfaces
may seriously affect handling and control of the ATV, and may
cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement whenever possible. If
you must ride on a paved surface, go slowly and do not make
sudden turns or stops.
SAFETY
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this ATV on any public street, road or highway,
even a dirt or gravel one.
In many states it is illegal to operate ATVs on public streets,
roads and highways.
26
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an approved helmet, eye
protection and protective clothing.
WHAT CAN HAPPEN
Operating without an approved helmet increases your
chances of a severe head injury or death in the event of an
accident.
Operating without eye protection can result in an accident and
increases your chances of a severe injury in the event of an
accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet which fits properly.
You should also wear: eye protection (goggles or face shield);
gloves; boots; long-sleeved shirt or jacket; and long pants.
SAFETY
27
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming alcohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while driving this
ATV.
WARNING
POTENTIAL HAZARD
Operating this ATV at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the ATV, which can
result in an accident.
HOW TO AVOID THE HAZARD
Always travel at a speed which is proper for the terrain, visibility
and operating conditions; and your experience.
28
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