Owners Manual
Page 5
... the time of publication. Any reprinting or reuse of Polaris Industries Inc. Copyright 2006 Polaris Sales Inc. Printed in this publication are registered trademarks of the depictions and/or procedures contained within this publication. All information contained within , whether whole or in this publication is expressly prohibited. Depictions and/or procedures in U.S.A. 2007 Sportsman 500 EFI Owner's Manual P/N 9920364 2 POLARIS and POLARIS...
... the time of publication. Any reprinting or reuse of Polaris Industries Inc. Copyright 2006 Polaris Sales Inc. Printed in this publication are registered trademarks of the depictions and/or procedures contained within this publication. All information contained within , whether whole or in this publication is expressly prohibited. Depictions and/or procedures in U.S.A. 2007 Sportsman 500 EFI Owner's Manual P/N 9920364 2 POLARIS and POLARIS...
Owners Manual
Page 10
... secured to the racks. 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. (545 kg). To prevent loss of control resulting in the park position. Be careful if load extends over on rough or hilly terrain, reduce speed and cargo. Safety Decals and Locations Discretionary Warning Tire Pressure/Load Warning SAFETY + + Discretionary Warning WARNING • Never operate...
... secured to the racks. 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. (545 kg). To prevent loss of control resulting in the park position. Be careful if load extends over on rough or hilly terrain, reduce speed and cargo. Safety Decals and Locations Discretionary Warning Tire Pressure/Load Warning SAFETY + + Discretionary Warning WARNING • Never operate...
Owners Manual
Page 21
Use only Polaris-approved accessories, and familiarize yourself with their function and effect on a Polaris ATV any other modifications to the vehicle, that may change the handling characteristics of the vehicle, or make any equipment that increase its speed or power. The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have...
Use only Polaris-approved accessories, and familiarize yourself with their function and effect on a Polaris ATV any other modifications to the vehicle, that may change the handling characteristics of the vehicle, or make any equipment that increase its speed or power. The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have...
Owners Manual
Page 45
Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. FEATURES AND CONTROLS The transmission gear selector is located on the right side of time. 42 H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the ATV is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is left unattended, always place the transmission in heavy pulling situations...
Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. FEATURES AND CONTROLS The transmission gear selector is located on the right side of time. 42 H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the ATV is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is left unattended, always place the transmission in heavy pulling situations...
Owners Manual
Page 47
... the engine RPM is controlled by the AWD switch. When the rear wheels regain traction, the demand drive unit will automatically engage any time the rear wheels lose traction. When the switch is in all times. If the rear wheels are spinning may remain in AWD, the demand drive unit will automatically disengage. CAUTION Switching to the length of AWD in reverse if the AWD switch is on or off while the vehicle is...
... the engine RPM is controlled by the AWD switch. When the rear wheels regain traction, the demand drive unit will automatically engage any time the rear wheels lose traction. When the switch is in all times. If the rear wheels are spinning may remain in AWD, the demand drive unit will automatically disengage. CAUTION Switching to the length of AWD in reverse if the AWD switch is on or off while the vehicle is...
Owners Manual
Page 48
...; The throttle is open (throttle is applied) • The transmission is equipped with Active Descent Control, always engage AWD before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatically engage when all four wheels when the vehicle descends a hill or incline. Active Descent Control (ADC) System FEATURES AND CONTROLS The ADC system (if equipped) allows engine braking to neutral or park 45
...; The throttle is open (throttle is applied) • The transmission is equipped with Active Descent Control, always engage AWD before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatically engage when all four wheels when the vehicle descends a hill or incline. Active Descent Control (ADC) System FEATURES AND CONTROLS The ADC system (if equipped) allows engine braking to neutral or park 45
Owners Manual
Page 50
Instrument Cluster FEATURES AND CONTROLS Rider Information Center The rider information center is in the AWD position. 3. Gear Indicator - AWD Indicator - Low Battery and Over Voltage - The word HOT displays if the engine overheats. It may have shut off to your Polaris dealer for 2.5 seconds at a higher RPM or recharge the battery to keep the battery charged. Check Engine Warning Indicator - Serious engine damage could result. 9. Service Interval/Diagnostic...
Instrument Cluster FEATURES AND CONTROLS Rider Information Center The rider information center is in the AWD position. 3. Gear Indicator - AWD Indicator - Low Battery and Over Voltage - The word HOT displays if the engine overheats. It may have shut off to your Polaris dealer for 2.5 seconds at a higher RPM or recharge the battery to keep the battery charged. Check Engine Warning Indicator - Serious engine damage could result. 9. Service Interval/Diagnostic...
Owners Manual
Page 58
... only light loads. See page 41. 2. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. See page 56. 6. Engine and Drivetrain Break-in period. 55 Careful treatment of the clutches and drive belt will result in more efficient performance and longer life for a proper break-in period, change both the oil and the filter at sustained idle. 5. Vary the throttle...
... only light loads. See page 41. 2. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. See page 56. 6. Engine and Drivetrain Break-in period. 55 Careful treatment of the clutches and drive belt will result in more efficient performance and longer life for a proper break-in period, change both the oil and the filter at sustained idle. 5. Vary the throttle...
Owners Manual
Page 61
... maintain stable driving conditions. Never install a hitch longer than 6 3/4" (17 cm). Maximum 6 3/4" (17 cm) 58 If towing a load, reduce rear rack cargo weight by the amount of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. Never install automotive accessories on your ATV warranty. When operating over rough or hilly terrain, reduce speed and cargo weight to the vehicle and will void your Polaris ATV...
... maintain stable driving conditions. Never install a hitch longer than 6 3/4" (17 cm). Maximum 6 3/4" (17 cm) 58 If towing a load, reduce rear rack cargo weight by the amount of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. Never install automotive accessories on your ATV warranty. When operating over rough or hilly terrain, reduce speed and cargo weight to the vehicle and will void your Polaris ATV...
Owners Manual
Page 62
... loss of control of the vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with loads that extend over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Avoid terrain or situations that cannot be centered, securely fasten the load and operate with extra caution. Carrying loads high on the rear rack. DO...
... loss of control of the vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with loads that extend over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Avoid terrain or situations that cannot be centered, securely fasten the load and operate with extra caution. Carrying loads high on the rear rack. DO...
Owners Manual
Page 97
... ft. Do not service axle nuts that all nuts are torqued to specification. lbs. (37 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. lbs. (37 Nm) 94 Torque the wheel nuts to the ground. 6. See your Polaris dealer. 1. Lock the parking brake. 3. MAINTENANCE Tires Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can...
... ft. Do not service axle nuts that all nuts are torqued to specification. lbs. (37 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. lbs. (37 Nm) 94 Torque the wheel nuts to the ground. 6. See your Polaris dealer. 1. Lock the parking brake. 3. MAINTENANCE Tires Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can...
Owners Manual
Page 99
.... 5. Oil from the rear of the headlight pod. 2. Wash the headlights frequently to cool before servicing. NOTE: Make sure the tab on the lower front corners of the pod. 3. Hot components can result in the housing. 8. Remove the screw from your skin leaves a residue, causing a hot spot that will shorten the life of the pod. 4. MAINTENANCE Lights When servicing a halogen...
.... 5. Oil from the rear of the headlight pod. 2. Wash the headlights frequently to cool before servicing. NOTE: Make sure the tab on the lower front corners of the pod. 3. Hot components can result in the housing. 8. Remove the screw from your skin leaves a residue, causing a hot spot that will shorten the life of the pod. 4. MAINTENANCE Lights When servicing a halogen...
Owners Manual
Page 100
... or downward. 1. Tilt the headlamp upward or downward. 3. Place the transmission in PARK. 2. Use the following procedure to the center of the headlamp. 2. Start the engine.Turn the headlight switch to the desired position by turning the knob either clockwise or counterclockwise. The most intense part of the headlight beam should be two inches (5 cm) below the mark on the...
... or downward. 1. Tilt the headlamp upward or downward. 3. Place the transmission in PARK. 2. Use the following procedure to the center of the headlamp. 2. Start the engine.Turn the headlight switch to the desired position by turning the knob either clockwise or counterclockwise. The most intense part of the headlight beam should be two inches (5 cm) below the mark on the...
Owners Manual
Page 101
Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. 5. Unplug the headlamp from the speedometer. 4. MAINTENANCE Lights Headlight Housing Replacement 1. NOTE: The distance from the locking tabs. 7. Adjust the headlight aim by turning the adjusting knob. 5 1/8" (13 cm) 98 Pull the headlight housing up to release it from the headlight mounting tabs. 6. Reverse the steps to remove it from the headlamp parting line...
Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. 5. Unplug the headlamp from the speedometer. 4. MAINTENANCE Lights Headlight Housing Replacement 1. NOTE: The distance from the locking tabs. 7. Adjust the headlight aim by turning the adjusting knob. 5 1/8" (13 cm) 98 Pull the headlight housing up to release it from the headlight mounting tabs. 6. Reverse the steps to remove it from the headlamp parting line...
Owners Manual
Page 120
... drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change fluids as recommended in and around the piston rings and ring lands, coating the cylinder with a protective film of Premium 4 Synthetic 0W40 engine oil. Cleaning and Storage Storage Tips MAINTENANCE Fluid Levels Inspect the fluid levels. Apply dielectric grease to specification. 4. If Polaris fuel system...
... drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change fluids as recommended in and around the piston rings and ring lands, coating the cylinder with a protective film of Premium 4 Synthetic 0W40 engine oil. Cleaning and Storage Storage Tips MAINTENANCE Fluid Levels Inspect the fluid levels. Apply dielectric grease to specification. 4. If Polaris fuel system...
Owners Manual
Page 126
... gas tank or fuel lines. Use the throttle quickly and effectively. RPM/low ground speed Utility use fast, objects from water Dry out the PVT. Climbing over large Shift the transmission to 7 times. See page 106. WARNING: Excessive throttle may cause loss of control and vehicle overturn. Inspect clutch seals for or snow ingestion into the damage if repeated leaking occurs. Slow/easy clutch engage- With the transmission...
... gas tank or fuel lines. Use the throttle quickly and effectively. RPM/low ground speed Utility use fast, objects from water Dry out the PVT. Climbing over large Shift the transmission to 7 times. See page 106. WARNING: Excessive throttle may cause loss of control and vehicle overturn. Inspect clutch seals for or snow ingestion into the damage if repeated leaking occurs. Slow/easy clutch engage- With the transmission...
Owners Manual
Page 131
SPECIFICATIONS Sportsman 500 EFI Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type Front Suspension Rear Suspension * Based on EU Directive 76/432/EC 1200 ...
SPECIFICATIONS Sportsman 500 EFI Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type Front Suspension Rear Suspension * Based on EU Directive 76/432/EC 1200 ...
Owners Manual
Page 132
SPECIFICATIONS Sportsman 500 EFI Shift Type Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Side Lever (H/L/N/R/P) 23.91:1 16.30:1 10.49:1 3.82:1 26x8-12 / 5 psi 26x11-12 / 5 psi Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (37.5 watt...
SPECIFICATIONS Sportsman 500 EFI Shift Type Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Side Lever (H/L/N/R/P) 23.91:1 16.30:1 10.49:1 3.82:1 26x8-12 / 5 psi 26x11-12 / 5 psi Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (37.5 watt...
Owners Manual
Page 136
... requested from country to Safety Recalls. This policy does not apply to vehicles registered to government officials or military personnel on assignment outside the country where your vehicle to perform the warranty repair. Outside the Country where your vehicle was purchased: If you move . Upon residence verification, the servicing dealer will be sure to contact Polaris Customer Assistance and the...
... requested from country to Safety Recalls. This policy does not apply to vehicles registered to government officials or military personnel on assignment outside the country where your vehicle to perform the warranty repair. Outside the Country where your vehicle was purchased: If you move . Upon residence verification, the servicing dealer will be sure to contact Polaris Customer Assistance and the...
Owners Manual
Page 141
... Rider Information Center ...47-53 Riding Gear...10-11 S Safety Decals "No Passenger" Warning ...8 Age 16 Warning ...8 All Wheel Drive Switch ...9 Clutch Cover Warning ...9 Discretionary Warning ...7 General Warning...6 Hitch Capacity Label ...9 Rack Warning, Front and Rear . . 9 Reverse Override Warning ...9 Tire Pressure/Load Warning...7 Safety Training ...13 Service Interval Programming ...51 Severe Use ...72 Side Panel Removal ...92 Sidehilling...64 Signal Words ...14 M Maintenance Chart ...72-76 Master Cylinder ...38 Mode Switch ...34 Modifications ...18 N Noise Emission Control System...
... Rider Information Center ...47-53 Riding Gear...10-11 S Safety Decals "No Passenger" Warning ...8 Age 16 Warning ...8 All Wheel Drive Switch ...9 Clutch Cover Warning ...9 Discretionary Warning ...7 General Warning...6 Hitch Capacity Label ...9 Rack Warning, Front and Rear . . 9 Reverse Override Warning ...9 Tire Pressure/Load Warning...7 Safety Training ...13 Service Interval Programming ...51 Severe Use ...72 Side Panel Removal ...92 Sidehilling...64 Signal Words ...14 M Maintenance Chart ...72-76 Master Cylinder ...38 Mode Switch ...34 Modifications ...18 N Noise Emission Control System...