Owners Manual
Page 4
... latest product information at the time of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within , whether whole or in U.S.A. 2010 Sportsman 500 HO International Owner's Manual P/N 9922553 2 No liability can be accepted for reference use only. Any reprinting or reuse of production components, some minor discrepancies may result between the actual vehicle and the information presented in...
... latest product information at the time of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within , whether whole or in U.S.A. 2010 Sportsman 500 HO International Owner's Manual P/N 9922553 2 No liability can be accepted for reference use only. Any reprinting or reuse of production components, some minor discrepancies may result between the actual vehicle and the information presented in...
Owners Manual
Page 7
Review this Polaris vehicle. Equipment Modifications The warranty on your Polaris vehicle may change vehicle handling. Use only Polaris-approved accessories. Know their function and effect on safety training course. Safety Training When you fail to follow the warnings in serious injury or death. INTRODUCTION WARNING Failure to take proper precautions. If you purchased a used Polaris vehicle from a party other than a Polaris dealer, please request free safety training from any...
Review this Polaris vehicle. Equipment Modifications The warranty on your Polaris vehicle may change vehicle handling. Use only Polaris-approved accessories. Know their function and effect on safety training course. Safety Training When you fail to follow the warnings in serious injury or death. INTRODUCTION WARNING Failure to take proper precautions. If you purchased a used Polaris vehicle from a party other than a Polaris dealer, please request free safety training from any...
Owners Manual
Page 34
... load weight when cargo is approved OFF-ROAD ONLY. Secure off -centered loads that extend over rough or hilly terrain, reduce speed, cargo and towed load to maintain stable driving conditions. • DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on only one rack may cause the vehicle to overturn. • TOWING is high. Unsecured loads can alter vehicle handling and may...
... load weight when cargo is approved OFF-ROAD ONLY. Secure off -centered loads that extend over rough or hilly terrain, reduce speed, cargo and towed load to maintain stable driving conditions. • DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on only one rack may cause the vehicle to overturn. • TOWING is high. Unsecured loads can alter vehicle handling and may...
Owners Manual
Page 43
... throttle settings during starting a cold engine. Use either leaded or unleaded gasoline with ethanol content greater than 10%, such as E-85 fuel. FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to clean the fuel filter. ON OFF 41 Do not use fuel with a minimum pump octane of operation or annually. Fuel Valve The fuel valve is located under the front storage box cover. Fuel Tank Cap Fuel Filter The in starting . OFF: For vehicle...
... throttle settings during starting a cold engine. Use either leaded or unleaded gasoline with ethanol content greater than 10%, such as E-85 fuel. FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to clean the fuel filter. ON OFF 41 Do not use fuel with a minimum pump octane of operation or annually. Fuel Valve The fuel valve is located under the front storage box cover. Fuel Tank Cap Fuel Filter The in starting . OFF: For vehicle...
Owners Manual
Page 46
... FEATURES AND CONTROLS All Wheel Drive (AWD) System The AWD switch may remain in AWD. Tip: The override switch allows activation of time the vehicle may be turned on , the vehicle is on . If the switch is locked, providing maximum traction. AWD will not disengage until engine speed is needed. The demand drive unit automatically engages when the rear wheels lose traction. Engage AWD before switching to AWD while the rear wheels are at all times and the differential...
... FEATURES AND CONTROLS All Wheel Drive (AWD) System The AWD switch may remain in AWD. Tip: The override switch allows activation of time the vehicle may be turned on , the vehicle is on . If the switch is locked, providing maximum traction. AWD will not disengage until engine speed is needed. The demand drive unit automatically engages when the rear wheels lose traction. Engage AWD before switching to AWD while the rear wheels are at all times and the differential...
Owners Manual
Page 48
... Gear N = Neutral R = Reverse Gear 2 P = Park 2. Service Interval/Diagnostic Mode Indicator 5. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to your Polaris dealer for 2.5 seconds at start-up. Odometer/Tachometer/Tripmeter/ Hour Meter 6. Check Engine Warning Indicator - All segments will blink. Mode Indicator 46 The word HOT displays if the engine overheats. FEATURES AND CONTROLS Instrument Cluster...
... Gear N = Neutral R = Reverse Gear 2 P = Park 2. Service Interval/Diagnostic Mode Indicator 5. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to your Polaris dealer for 2.5 seconds at start-up. Odometer/Tachometer/Tripmeter/ Hour Meter 6. Check Engine Warning Indicator - All segments will blink. Mode Indicator 46 The word HOT displays if the engine overheats. FEATURES AND CONTROLS Instrument Cluster...
Owners Manual
Page 54
Careful treatment of a new engine and drive components will increase the life and performance of your vehicle more efficient performance and longer life for these components. Vary the throttle positions. Change the oil and filter at full throttle or high speeds for extended periods during the first three hours of use the first two full tanks of operation, or the time it takes to familiarize...
Careful treatment of a new engine and drive components will increase the life and performance of your vehicle more efficient performance and longer life for these components. Vary the throttle positions. Change the oil and filter at full throttle or high speeds for extended periods during the first three hours of use the first two full tanks of operation, or the time it takes to familiarize...
Owners Manual
Page 61
... Inspect level; change yearly Inspect; clean if needed Battery X Demand drive fluid (front gearcase) X Rear gearcase oil (if equipped) X Transmission oil X Engine breather E filter (if equipped) X Perform these services. 59 clean; change yearly Inspect level; E Emission-Related Service Q Have an authorized Polaris dealer perform these procedures more often for vehicles subjected to severe use. test Inspect level; apply dielectric grease if replacing Inspect; replace as need ed. change coolant every 2 years...
... Inspect level; change yearly Inspect; clean if needed Battery X Demand drive fluid (front gearcase) X Rear gearcase oil (if equipped) X Transmission oil X Engine breather E filter (if equipped) X Perform these services. 59 clean; change yearly Inspect level; E Emission-Related Service Q Have an authorized Polaris dealer perform these procedures more often for vehicles subjected to severe use. test Inspect level; apply dielectric grease if replacing Inspect; replace as need ed. change coolant every 2 years...
Owners Manual
Page 62
... Inspect for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; lubricate; pressure test system yearly Perform a break-in oil change at one month Lubricate all fittings, pivots, cables, etc. adjust; replace as needed Inspect coolant strength seasonally; adjust; adjust Check for leaks Inspect Inspect X Front suspension X Rear suspension Carburetor float bowl Q Throttle Cable/ E ETC Switch E Q Choke cable E Carburetor air intake ducts/flange Drive belt Cooling system X Engine oil change X Oil filter change Inspect routing, condition Inspect; Inspect...
... Inspect for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; lubricate; pressure test system yearly Perform a break-in oil change at one month Lubricate all fittings, pivots, cables, etc. adjust; replace as needed Inspect coolant strength seasonally; adjust; adjust Check for leaks Inspect Inspect X Front suspension X Rear suspension Carburetor float bowl Q Throttle Cable/ E ETC Switch E Q Choke cable E Carburetor air intake ducts/flange Drive belt Cooling system X Engine oil change X Oil filter change Inspect routing, condition Inspect; Inspect...
Owners Manual
Page 65
... if Polaris Premium 4 oil is not used. Oil Specifications Model Sportsman 500 HO International Lubricant Premium 4 Synthetic 0W-40 Capacity 1.9 liters Drain Plug Torque 19-23 N-m 63 Polaris recommends the use a recommended oil. Follow the manufacturer's recommendations for ambient temperature operation. Mixing brands or using a non-recommended oil may need to provide the ultimate in lubrication performance and protection. MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Oil may...
... if Polaris Premium 4 oil is not used. Oil Specifications Model Sportsman 500 HO International Lubricant Premium 4 Synthetic 0W-40 Capacity 1.9 liters Drain Plug Torque 19-23 N-m 63 Polaris recommends the use a recommended oil. Follow the manufacturer's recommendations for ambient temperature operation. Mixing brands or using a non-recommended oil may need to provide the ultimate in lubrication performance and protection. MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Oil may...
Owners Manual
Page 75
... screw in gear. 3. Idle Screw 73 Start the engine and allow more information about jetting the ATV for conditions in elevation. MAINTENANCE Carburetor This vehicle is calibrated at the factory for optimal performance at altitudes ranging from your Polaris dealer, are serviceable only by Polaris dealers. Lock the parking brake. 4. Turn the screw out (counter-clockwise) to the carburetor and drive system can cause poor performance, overheating or PVT...
... screw in gear. 3. Idle Screw 73 Start the engine and allow more information about jetting the ATV for conditions in elevation. MAINTENANCE Carburetor This vehicle is calibrated at the factory for optimal performance at altitudes ranging from your Polaris dealer, are serviceable only by Polaris dealers. Lock the parking brake. 4. Turn the screw out (counter-clockwise) to the carburetor and drive system can cause poor performance, overheating or PVT...
Owners Manual
Page 87
MAINTENANCE Tires Wheel Removal/Installation Always use original equipment size and type when replacing tires. Loosen the wheel nuts slightly. 4. Place the wheel on page 84. 85 Torque the wheel nuts to raise the wheel slightly off the ground. 5. See torque chart on the hub. 8. Remove the wheel. 7. Install wheels properly. 1. Install the wheel nuts finger tight. 9. Position the vehicle on a level surface. 2. Place a suitable stand...
MAINTENANCE Tires Wheel Removal/Installation Always use original equipment size and type when replacing tires. Loosen the wheel nuts slightly. 4. Place the wheel on page 84. 85 Torque the wheel nuts to raise the wheel slightly off the ground. 5. See torque chart on the hub. 8. Remove the wheel. 7. Install wheels properly. 1. Install the wheel nuts finger tight. 9. Position the vehicle on a level surface. 2. Place a suitable stand...
Owners Manual
Page 90
Position the vehicle on the wall. Start the engine.Turn the headlight switch to the left or right. 88 Observe the headlight aim on a level surface. The most intense part of the headlight beam should be approximately 7.6 m from the floor to the center of the headlight and make a mark on the wall at the same height. Place the transmission in PARK. 3. MAINTENANCE Lights Headlight Beam Adjustment The...
Position the vehicle on the wall. Start the engine.Turn the headlight switch to the left or right. 88 Observe the headlight aim on a level surface. The most intense part of the headlight beam should be approximately 7.6 m from the floor to the center of the headlight and make a mark on the wall at the same height. Place the transmission in PARK. 3. MAINTENANCE Lights Headlight Beam Adjustment The...
Owners Manual
Page 91
... rack cover. 3. Go to reassemble the headlight. Hot components can result in PARK. 2. Remove the lamp. Oil from the back of the lamp. Do not service the headlamps until they've cooled. Remove the plug at the back of the lamp. 1. Apply dielectric grease to disconnect it . Wash the headlights and taillights frequently. Position Light Headlamp Collar Socket 89 MAINTENANCE Lights Poor lighting...
... rack cover. 3. Go to reassemble the headlight. Hot components can result in PARK. 2. Remove the lamp. Oil from the back of the lamp. Do not service the headlamps until they've cooled. Remove the plug at the back of the lamp. 1. Apply dielectric grease to disconnect it . Wash the headlights and taillights frequently. Position Light Headlamp Collar Socket 89 MAINTENANCE Lights Poor lighting...
Owners Manual
Page 110
... charge. Polishing the Vehicle Polaris recommends the use of your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Radiator • Transmission seals • Brakes • Cab and body panels • Electrical components • Switches and controls • Labels and decals If an informational or graphic label becomes illegible or comes off, contact your vehicle. • Always use...
... charge. Polishing the Vehicle Polaris recommends the use of your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Radiator • Transmission seals • Brakes • Cab and body panels • Electrical components • Switches and controls • Labels and decals If an informational or graphic label becomes illegible or comes off, contact your vehicle. • Always use...
Owners Manual
Page 113
... of gasoline. 7. Reinstall the spark plugs. Torque to the inside of engine oil into the plug holes. 3. Reinstall the caps. 5. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be forced in the Periodic Maintenance Chart beginning on page 57. • Demand drive unit (front gearcase) • Transmission • Rear gearcase (if equipped) • Brake fluid (change every two years and...
... of gasoline. 7. Reinstall the spark plugs. Torque to the inside of engine oil into the plug holes. 3. Reinstall the caps. 5. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be forced in the Periodic Maintenance Chart beginning on page 57. • Demand drive unit (front gearcase) • Transmission • Rear gearcase (if equipped) • Brake fluid (change every two years and...
Owners Manual
Page 116
... Sportsman 500 HO International Gross Vehicle Weight Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box Capacity Receiver Hitch Tongue Capacity (Off-road use only) Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Ignition...
... Sportsman 500 HO International Gross Vehicle Weight Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box Capacity Receiver Hitch Tongue Capacity (Off-road use only) Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Ignition...
Owners Manual
Page 117
SPECIFICATIONS Sportsman 500 HO International Driving System Type Front Suspension Rear Suspension Shift Type Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic PVT (Polaris Variable Transmission) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 9.5" (24 cm) travel Side Lever (H/L/N/R/P) 23.91:1 16.30:1 10.49:1 3.82:1 25x8-12 / 5 psi (34.5 kPa) 25x12.5-12 / 5 psi (34.5 kPa) All-wheel hydraulic disc...
SPECIFICATIONS Sportsman 500 HO International Driving System Type Front Suspension Rear Suspension Shift Type Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic PVT (Polaris Variable Transmission) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 9.5" (24 cm) travel Side Lever (H/L/N/R/P) 23.91:1 16.30:1 10.49:1 3.82:1 25x8-12 / 5 psi (34.5 kPa) 25x12.5-12 / 5 psi (34.5 kPa) All-wheel hydraulic disc...
Owners Manual
Page 119
... break-in Always break in gas tank or fuel lines. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to engage clutch. The belt will become more frequently. ment Towing/pushing at least 5 minutes. Carefully use fast, aggressive throttle application to 7 times. position Belt slippage from a stopped and vehicle overturn. Poor engine performance Check for fouled plugs or foreign material in a new...
... break-in Always break in gas tank or fuel lines. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to engage clutch. The belt will become more frequently. ment Towing/pushing at least 5 minutes. Carefully use fast, aggressive throttle application to 7 times. position Belt slippage from a stopped and vehicle overturn. Poor engine performance Check for fouled plugs or foreign material in a new...
Owners Manual
Page 125
... which has been damaged by external stress, heat, cold or contamination; The following items: Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty applies to any other foreign substance ingestion/contamination; Warranty will not apply to the product only...
... which has been damaged by external stress, heat, cold or contamination; The following items: Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty applies to any other foreign substance ingestion/contamination; Warranty will not apply to the product only...