Sportsman Forest 500 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.
Before you operate this vehicle, read the owner’s manual For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No.
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory Motorcycles® Always follow the instructions and recommendations in this manual.
POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS Industries Inc. Copyright 2011 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.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Emission Control Systems . . . . . . . . . . . . . . . 62 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Specifications . .
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. DANGER A DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
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 Never operate this vehicle without proper instruction. Take a training course.
INTRODUCTION 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.
SAFETY Operator Safety WARNING 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 vehicle. Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
SAFETY Operator 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. Never attempt jumps or other stunts.
SAFETY Operator Safety Always inspect your POLARIS 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 53. Keep both hands on the handlebars. Keep your 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 19.
SAFETY Operator Safety 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. 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 25. Always follow the procedures outlined in this manual for driving on hills. See page 22.
SAFETY Operator 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 26. Always follow the procedures outlined in this manual for operating over obstacles. See page 21. 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 20.
SAFETY Operator Safety Always follow the procedures outlined in this manual for driving in reverse. See page 31. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify this POLARIS 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.
SAFETY Operator Safety Never operate the vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party. 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.
SAFETY 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.
SAFETY Safety Labels and Locations “No Passenger” Warning Rack Warning Clutch Cover Alert Rack Warning Tire Pressure/ Load Alert “No Passenger” Warning WARNING - NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Tire Pressure/Load Alert 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. (546 kg).
SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Eye Protection Helmet Long Sleeves Gloves Long Pants Boots 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.
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.
SAFETY Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 2. Apply the brakes. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5. Check your surroundings and determine your path of travel. 6. Release the brakes. 7. Slowly squeeze the throttle lever toward the handlebar to begin driving. 8. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.
SAFETY Driving Safely Turning the Vehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 3. Practice turning at slow speeds before attempting to turn at faster speeds.
SAFETY Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Engage AWD before wheels begin to lose traction. 3. Be alert. Watch the trail. Avoid quick, sharp turns. Tip: To correct a rear wheel skid, turn the handlebars in the same direcSideways tion as the skid and shift skid body weight forward.
SAFETY Driving Safely Driving Over Obstacles 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. Watch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches. Always follow the procedures outlined in this manual for operating over obstacles.
SAFETY Driving Safely Driving Uphill 25 Maximum Whenever traveling uphill, follow these precautions: 1. Avoid steep hills (25 maximum). 2. Check the terrain carefully. 3. Avoid hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill. 6. Keep your feet on the footrests. 7. Drive at a steady rate of speed to avoid stalling. 8. Be alert. Be prepared to take emergency action. This may include dismounting quickly. 9.
SAFETY Driving Safely Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. Apply the brakes gradually. When fully stopped, lock the hydraulic parking brake. See page 39. Dismount on the uphill side, or to either side if the vehicle is pointed straight uphill. Turn the vehicle around using the K-Turn. See page 26.
SAFETY Driving Safely Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with excessively slippery or loose surfaces. 3. Shift your weight uphill. 4. Avoid crossing the sides of steep hills. 5. Keep your feet on the footrests. 6. Steer slightly into the hill. 7.
SAFETY Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Check the terrain carefully. 2. Avoid hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side. Drive straight downhill. 6. Shift your weight rearward. 7. Apply the brakes slightly to aid in slowing.
SAFETY Driving Safely Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. 2. 3. 4. Stop the vehicle. Keep your weight uphill. Lock the hydraulic parking brake. Leave the transmission in forward gear. Turn the engine off. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. 5. Stay uphill of the vehicle and turn the handlebars full left. 6.
SAFETY Driving Safely Turning Around on a Hill (K-Turn) 8. 9. 10. 11. 12. 13. Lock the hydraulic parking brake. Remount from the uphill side. Keep your weight uphill. Apply the foot brake. With the transmission still in forward, start the engine. Squeeze and release the brake lever to release the parking brake. Release the foot brake and drive slowly downhill. Control speed with either the hand or foot brake until the vehicle is on level ground.
SAFETY Driving Safely Driving Through Water Maximum Depth Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes. 3. Choose a crossing where both banks have gradual inclines. 4. Drive slowly.
SAFETY Driving Safely Driving Through Water If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 100. Have the vehicle serviced by your dealer promptly. If water has been ingested into the transmission (PVT), follow the procedure on page 105. Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water.
SAFETY Driving Safely Parking on an Incline Avoid parking on an incline. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Always block the rear wheels on the downhill side. 4. Turn the fuel valve off.
SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly. 4. Apply the foot brake lightly for stopping. 5. Avoid turning at sharp angles. 6. Do not use the override switch unless additional power is required for vehicle movement. Use with caution. Tip: Reverse speed is greatly increased when the override switch is used. Do not operate at full throttle.
SAFETY Driving Safely Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the vehicle warning labels. • Never exceed the stated load capacity for this vehicle. • REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes.
SAFETY Driving Safely Hauling Cargo 2/3 1/3 Towing Loads Towing is approved OFF-ROAD ONLY. Operating this vehicle with a trailer on public roads is prohibited. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15. Unbraked Trailer Towing Capacity is 1786 lbs. (810 kg) based on EU Directive 76/432/EC. Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your warranty.
FEATURES AND CONTROLS Switches Momentary High-Beam Switch All Wheel Drive Switch Winch Switch Mode/Reverse Override Switch Choke Main Key Switch Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 45. To gain additional power while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse speed limit function.
FEATURES AND CONTROLS 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 PARKING LIGHTS ON position. The parking lights and taillights are on in this position. See page 54 for starting procedures. Engine Stop Switch The engine will not start or run when the switch is in the OFF position.
FEATURES AND CONTROLS 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 to end the signal. Horn Switch horn. Hazard Switch Press the horn switch to sound the Turn Signal Switch Hazard Warning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously.
FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle. 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 vehicle with sticking or improperly operating throttle controls.
FEATURES AND CONTROLS 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. Foot Brake 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.
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. 4. Release the brake lever. 5. 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.
FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. Tip: Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 1. Turn the handlebars to the full left position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key. 4. Reverse the procedure to unlock the steering. The handlebars are locked in the full left position when the steering is locked.
FEATURES AND CONTROLS Fuel Valve The fuel valve is located in the left front wheel well. OFF: For vehicle storage and when transporting. ON: For normal operation. Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 54 for correct choke and throttle settings during starting. ON Fuel Valve OFF Fuel Tank Cap Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually.
FEATURES AND CONTROLS 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 To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. Gear Selector Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage. Whenever the vehicle is left unattended, always place the transmission in PARK.
FEATURES AND CONTROLS Recoil Starter (if equipped) If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 54, cranking the engine with the recoil Handle starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly. Recoil Starter 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.
FEATURES AND CONTROLS All Wheel Drive (AWD) System The AWD switch may be turned on or off while the vehicle is moving. AWD will not engage until engine speed is below 3100 RPM. AWD remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in AWD. If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction. Engage AWD before getting into situations where maximum traction is needed.
FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 34 for additional information.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 34. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1. Turn the key switch off and wait 10 seconds. 2. Lock the parking brake. 3. Place the transmission in neutral. 4. Hold the mode/reverse override button and turn the key switch on.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). This screen is for informational purposes only. Please see your dealer for all major repairs.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference. To reset the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3.
OPERATION Fuel Safety WARNING 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.
OPERATION Break-In Period The break-in period for your new POLARIS vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and performance of your vehicle more than following the procedures for a proper breakin. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
OPERATION Pre-Ride Checklist Item Remarks Page Foot brake Ensure proper operation 38 Hand brake/lever travel Ensure proper operation 85 Brake fluid Ensure proper level 82 Front suspension Inspect, lubricate if necessary 68 Rear suspension Inspect, lubricate if necessary 68 Steering/steering lock Unlock the steering; ensure free operation 40 Tires Inspect condition and pressure 90 Wheels/fasteners Inspect, ensure fastener tightness 90 Frame nuts, bolts, fasteners Inspect, ensure t
OPERATION Starting the Engine 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. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Turn the fuel valve on. 4. Sit on the vehicle. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged. Tip: Do not use the choke if starting a warm engine.
OPERATION Starting the Engine 7. Do not press the throttle while starting the engine. Turn the ignition key past the PARKING LIGHTS ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. 8. If the engine does not start, release the starter and wait five seconds. 9. Repeat steps 7 and 8 until the engine starts. Operating the vehicle immediately after starting could cause engine damage.
WINCH GUIDE The responsibility for safe operation of the winch ultimately rests with you, the operator. Read and understand all safety precautions and operating instructions before operating the winch. Careless operation can result in serious injury. DO NOT use the winch to lift or move people. Winch Safety Precautions 1. Be alert. Do not operate the winch under the influence of drugs, alcohol or medication. 2. Practice using the winch so you are prepared to use it in an emergency situation.
WINCH GUIDE Winch Cable Care 1. The life of a cable is directly related to the care it receives. The wire cable on a new winch (and any replacement cables) must be respooled under a minimum of a 100-lb. (45.4-kg) load before use. Failure to do this will result in cable damage. 2. Inspect all cable before use. Mashed, pinched, frayed or kinked areas severely reduce the load-carrying capability. Replace damaged cable promptly. 3. Prevent kinks before they occur. A A. B. C. This is a start of a kink.
WINCH GUIDE Winch Preparation and Inspection DANGER Wear heavy leather gloves whenever handling cable. Do not allow the cable to slip through your hands, even with gloves on. When handling the hook, always use a handsaver. Never place fingers into the hook. Placing fingers in the hook could result in injury. WARNING Inspect the switch and wiring for cracks, pinched spots, frayed wire or loose connections. A damaged, shortened lead could cause the winch to operate as soon as it is plugged in.
WINCH GUIDE Winch Rigging WARNING Take your time when rigging and use extra caution. Improper rigging can result in injury in addition to damage to the vehicle and equipment. Never handle the cable or rigging while another person is at the control switch. 1. Use a nylon sling to attach the cable to an anchor point. CAUTION! Do not attach the hook back onto the cable. Doing so can cause the cable to break. WARNING Always use a handsaver. Do not hold the hook with your hand.
WINCH GUIDE Winch Operation NOTICE: This winch is designed for intermittent use. Prolonged use may result in damage due to overheating. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 60 Use common sense. Take your time. Think through the situation. Pay attention to what is going on when you are winching. DO NOT overheat the winch motor. During extended winching, stop and feel the winch motor. The motor should be cool enough to touch. If not, allow the motor to cool before continuing.
WINCH GUIDE Winch Operation 13. Use as much cable as possible when pulling. Additional wraps of cable on the spool will significantly reduce the pulling power of your winch. If the winch is still not capable of pulling the load, use a snatch block. 14. Never pull with less than five wraps of cable on the spool. 15. Inspect the condition of the cable prior to pulling. If the cable is frayed or damaged, replace it as soon as possible. 16. DO NOT submerge the winch in water.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Spark Arrester Your POLARIS vehicle has a spark arrester that was designed for on-road and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.
MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 45. Record maintenance and service in the Maintenance Log beginning on page 131. Service and adjustments are important for proper vehicle operation.
MAINTENANCE Periodic Maintenance Chart WARNING Improperly performing the procedures marked with a could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized POLARIS dealer perform these services. Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Hours Calendar Engine oil change (break-in) General lubrication Shift linkage Remarks (whichever comes first) Kilometers - 1M - Perform a break-in oil change at one month 50 3M 800 Lubricate all fittings, pivots, cables, etc.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Remarks Kilometers Spark plug 100 12 M 1600 Inspect; replace as needed Wiring 100 12 M 1600 Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
MAINTENANCE Lubrication Guide Always check and change fluids and lubricate greaseable components at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS Performance Synthetic 2W-50 See page 69. Brake Fluid DOT 4 Only See page 82. Transmission Oil AGL PLUS Transmission Fluid See page 75.
MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 122 for the part numbers of POLARIS products.
MAINTENANCE Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Remove the dipstick. Wipe it dry with a clean cloth. 6. Reinstall the dipstick completely. Dipstick 7. Remove the dipstick and check the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill. Safe Range { Add Oil 8. Reinstall the dipstick.
MAINTENANCE Engine Oil Oil Change Hot oil may result in serious burns. Do not allow hot oil to contact skin. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for two minutes. 4. Stop the engine. 5. Clean the area around the drain plug. 6. Place a drain pan under the oil tank. 7. Remove the drain plug. 8. Drain the oil. Drain Plug Screen Fitting New Sealing Washer 9. Clean the drain plug.
MAINTENANCE Engine Oil Oil Change 11. Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank. Clean the fitting. The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape. 12. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the Alignment Mark tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank. Tip: Do not over-tighten.
MAINTENANCE Engine Oil Oil Change 20. Remove the dipstick. 21. Add 1.9 liters of recommended oil. If the sump is not drained, add about 1.6 liters initially. 22. Reinstall the dipstick. 23. Place the transmission in PARK. 24. Prime the oil pump using the procedure on page 74. 25. Stop the engine. Check for oil leaks. Safe Range { 26. Check the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill. 27. Reinstall the dipstick. 28. Discard used oil and filter properly.
MAINTENANCE Engine Oil Oil Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 5 cm connection between the oil tank and pump inlet has been disconnected. 1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the Clamp vent line's pressure relief slit. Pressure 2. Start the engine. Allow it to idle Relief Slit for 10-20 seconds. 3. Remove the vent line clamp. If the line is bled properly, you should hear a rush of air.
MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 122 for the part numbers of POLARIS products. Oil Recommendations Lubricant Oil Change Capacity Fill Plug Torque Drain Plug Torque AGL PLUS Transmission Fluid 948 ml 27-34 N-m 27-34 N-m Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Check the oil level.
MAINTENANCE Transmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. 4. 5. 6. 7. 8. 9. 10. 11. 76 Remove the fill plug. Remove the drain plug. Drain the oil into a drain pan. Clean the drain plug. Reinstall the drain plug. Torque to specification. See page 75. Add the recommended oil. Reinstall the fill plug. Torque to specification. Check for leaks. Discard used oil properly.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Demand Drive Unit Demand Drive Plus Fluid 265 ml 11-14 N-m 15 N-m Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 122 for the part numbers of POLARIS products. Maintain the fluid level at the bottom of the fill hole threads. Fill Plug Fill Level Drain Plug Fluid Level 1.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. Drain the fluid into a drain pan. 5. Clean the drain plug. 6. Reinstall the drain plug. Torque to specification. See page 77. 7. Add the recommended fluid. 8. Reinstall the fill plug. Torque to specification. 9. Check for leaks. 10. Discard used oil properly.
MAINTENANCE Carburetor This vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
MAINTENANCE Cooling System Any time the cooling system has been drained for maintenance or repair, replace the coolant with a fresh mixture of antifreeze and water. Drain the cooling system every two years. Add fresh coolant. POLARIS recommends the use of POLARIS Premium 60/40 antifreeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is premixed and ready to use. Do not dilute with water.
MAINTENANCE Cooling System Radiator Coolant Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box cover. 2. Remove the access panel screws. Squeeze the outer edges of the panel inward to remove the panel. 3. Remove the radiator pressure Radiator cap. Cap 4. If coolant is not visible, slowly add coolant through the radiator filler neck. 5. Reinstall the pressure cap.
MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.
MAINTENANCE Brake Fluid Hand Brake Master Cylinder The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. Indicator Window 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View the fluid level through the indicator window (eye) on the top of the master cylinder. Full Low Tip: The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear. 3.
MAINTENANCE Brake Fluid Foot Brake 1. Position the vehicle on a level surface. 2. Remove the seat. 3. View the fluid level in the master cylinder. 4. Maintain the fluid level between the minimum and maximum marks. Do not overfill.
MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily under normal operation. 1. Always keep brake fluid at an adequate level. See page 82. 2. Check the brake systems regularly for fluid leaks. 3.
MAINTENANCE Toe Alignment Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Place the handlebars in a Stand straight-ahead position. 3. Tie a length of string String between two stands as shown in the illustration.
MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle. Handlebar Adjustment The handlebars can be adjusted for rider preference. Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control.
MAINTENANCE Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it. Footwell Removal Rivets 1. Remove the four screws on the bottom of the footwell. 2. Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders. 3. Remove the footwell.
MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. Boot 3. Loosen the adjuster lock nut. Lock Nut Adjuster 4. Rotate the boot to turn the adjuster until 1.6-3.2 mm of freeplay is achieved at the thumb lever. Move the throttle lever back and forth while adjusting. 1.6-3.2 mm 5. Tighten the lock nut. 6.
MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. • Maintain proper tire pressure as described on the label on your vehicle and in the specifications section of the owner's manual. • Use only original equipment size and type when replacing tires. • Make sure the wheels are installed properly. • Replace tires when the tread depth measures 3 mm or less.
MAINTENANCE Tires Wheel Removal/Installation Always use original equipment size and type when replacing tires. Install wheels properly. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 5. Remove the wheel nuts. 6. Remove the wheel. 7. Place the wheel on the hub. 8. Install the wheel nuts finger tight. 9. Lower the vehicle to the ground. 10.
MAINTENANCE Air Filter Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the seat. 4. Release the air box cover clips. 5. Remove the air box cover. 6. Loosen the hose clamp. 7. Remove the filter. 8. Remove the pre-filter from the filter. Pre-Filter 9. Wash the pre-filter in soapy water. Rinse and air dry. 10.
MAINTENANCE Breather Filter/Hose The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 88. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace a damaged or clogged filter. Breather Filter 4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. 5.
MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. Include rider weight on the seat when measuring. 7.6 m X X 5 cm 4. Start the engine.Turn the headlight switch to high beam. 5.
MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Parking Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
MAINTENANCE Lights Taillight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counter-clockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6. Reinstall all components in reverse order. Front Turn Signal Replacement If a front turn signal light becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly. Rear Turn Signal Lamp Replacement 1.
MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a compartment. 1. Open the front box cover. 2. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage. 3. Secure the front box cover.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 120 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition Torque Specification New Spark Plug 12-15 N-m Previously Installed Spark Plug 23-27 N-m Spark Plug Inspection Spark plug condition is indicative of engine operation.
MAINTENANCE Spark Plugs Spark Plug Removal 1. Remove the left side panel. See page 88. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise to remove it. 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation. 5. Reinstall the spark plug. Torque to specification. See page 98. 6. Reinstall the spark plug cap.
MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following procedure. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. 1. Move the vehicle out of the water. 2. Turn the fuel valve off. 3. Drain any water found in the air box. 4. Remove the spark plug. 5.
MAINTENANCE Vehicle Immersion 7. Dry the spark plug. Reinstall the plug or install a new plug. Torque to specification. See page 98. 8. Tighten the carburetor drain screw. 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Have the vehicle serviced by your dealer promptly, whether you succeed in starting it or not. 12. If water has been ingested into the PVT, follow the procedure on page 105 for drying out the PVT.
MAINTENANCE Spark Arrester Occasionally, the spark arrester may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrester. Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors. Exhaust contains poisonous carbon monoxide gas. Never go under the vehicle while it's inclined. Remove any combustible materials from the area. Wear eye protection and leather work gloves.
MAINTENANCE Spark Arrester 6. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves. 7. Lightly tap on the exhaust pipe with a rubber mallet while repeating step 5. 8. If particles are still suspected to be in the muffler, elevate the rear of the vehicle 30 cm higher than the front. Block the wheels. 9. Place the transmission in PARK. Repeat steps 5 to 7 until 30 cm no more particles are expelled. 10. Stop the engine. Allow the arrester to cool. 11.
MAINTENANCE PVT System Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product.
MAINTENANCE PVT System When To Use Low Range and High Range Condition Operating at speeds less than 11 km/h Range to Use Low Towing heavy loads Low Operating in rough terrain (swamps, mountains, etc.) Low Operating at speeds greater than 11 km/h High PVT Drying There may be some instances when water is accidently ingested into the PVT system. Dry it out before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the drain plug.
MAINTENANCE Recoil Housing (if equipped) Always drain the recoil housing after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug. Recoil Housing 1. Place the transmission in PARK. 2. Stop the engine. 3. Remove the drain screw on the bottom of the recoil housing. 4. Allow the housing to drain completely. 5. Reinstall the drain screw.
MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
MAINTENANCE Battery Battery Removal 1. 2. 3. 4. 5. 6. 7. 8. Place the transmission in PARK. Remove the seat. Disconnect the battery hold-down strap. Remove the battery cover (if equipped). On conventional batteries, remove the battery vent tube. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
MAINTENANCE Battery Battery Installation 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal selfdischarge.
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 108. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 109. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater. 3. When using an automatic charger, refer to the charger manufacturer's instructions for recharging.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. 1.
MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels.
MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
MAINTENANCE Cleaning and Storage Storage Tips Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 113. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 63. • Demand drive unit (front gearcase) • Transmission • Rear gearcase (if equipped) • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Treat the fuel system with POLARIS Carbon Clean. See page 116. 2. Remove the spark plug.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 63. Battery Storage See pages 110-111 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely support the vehicle with the tires slightly off the ground. 2. Be sure the storage area is well ventilated. 3. Cover the vehicle with a genuine POLARIS cover.
MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap and seat. 4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets.
SPECIFICATIONS SPORTSMAN FOREST 500 Maximum Weight Load 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 Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Engine Power Bore x Stroke Alternator Output Compression Ratio Fuel System Pilot Jet Main Jet Needle Jet Jet Needle Pil
SPECIFICATIONS SPORTSMAN FOREST 500 Front Suspension Rear Suspension Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Tires Type Front Tires Type Rear Brakes, Front/Rear Brakes, Auxiliary Parking Brake Hitch Winch Headlight Parking Lights Taillights Brake Light Instrument Cluster MacPherson strut with 8.2" (21 cm) travel Progressive rate with 9.5" (24 cm) travel 23.91:1 21.74:1 10.57:1 3.82:1 Off Road Style, Deep Tread Design Size 25x8-12 / 5 psi (34.
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2878068 2878069 2877922 2877923 2870465 2871654 2872277 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2872893 2871956 2871076 122 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (.95 l) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l) Gearcase / Transmission Lubricants AGL PLUS Transmission Fluid (.95 l) AGL PLUS Transmission Fluid (3.
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or speed (5-11 km/h) Insufficient warm-up at low ambient temperatures Solution Use low range. Use low range or turn around using the K-turn (see page 26). Drive at a higher speed or use low range more frequently. Warm the engine at least 5 minutes.
TROUBLESHOOTING Engine Does Not Rotate Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Solution Reset the breaker Recharge the battery to 12.
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent l
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Overuse of choke Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Solution Refuel, cycle key to O
WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS vehicle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. The duration of this warranty may vary depending on location.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed.
MAINTENANCE LOG DATE 132 KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 133
INDEX A D Accessories . . . . . . . . . . . . . . . . . . 118 Age Restrictions. . . . . . . . . . . . . . . . . 5 Air Filter . . . . . . . . . . . . . . . . . . . . . 92 All Wheel Drive Switch. . . . . . . . . . 34 All Wheel Drive System . . . . . . . . . 44 AWD System . . . . . . . . . . . . . . . . . . 44 Demand Drive Fluid . . . . . . . . . . 77-78 Drive Belt Wear/Burn . . . . . . . . . . . 123 Drivetrain Break-In . . . . . . . . . . . . . . 52 Driving Downhill. . . . . . . . . . . . . . . .
INDEX F M Foot Brake. . . . . . . . . . . . . . . . . . . . . 38 Footwell Removal. . . . . . . . . . . . . . . 88 Front Gearcase . . . . . . . . . . . . . . 77-78 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 41 Fuel Safety . . . . . . . . . . . . . . . . . . . . 51 Fuel Tank Cap. . . . . . . . . . . . . . . . . . 41 Fuel Valve. . . . . . . . . . . . . . . . . . . . . 41 Fuse Replacement . . . . . . . . . . . . . . . 97 Maintenance Chart . . . . . . . . . . . 63-67 Mirrors . . . . . . . . . . . .
INDEX R T Recoil Housing . . . . . . . . . . . . . . . 106 Recoil Starter . . . . . . . . . . . . . . . . . . 43 Reverse Operation . . . . . . . . . . . . . . 31 Reverse Override Switch . . . . . . . . . 34 Rider Information Center. . . . . . . 46-50 Riding Gear . . . . . . . . . . . . . . . . . 16-17 Taillight . . . . . . . . . . . . . . . . . . . . . . . 96 Throttle Cable Freeplay . . . . . . . . . . . 89 Throttle Lever . . . . . . . . . . . . . . . . . . 37 Tire Tread Depth . . . . . . . . . . . . . .
