Instruction/ maintenance manual of the product 500 EFI Touring Polaris
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1 WELCOME Thank you for purchasin g a Polaris vehicl e, an d welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products.
2 POLARIS and POLARIS TH E W A Y OUT are registered t rademarks of Polaris Indus - tries Inc. Copyright 2007 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication.
3 T ABLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F eatures and Controls . . . . . . . . . . . . . . . . . . . 36 Operation . . . . . . .
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5 KNOW Y OUR VEHICLE As the operator of the vehicle, y o u are responsible for your persona l safety , the safety of others (including your passenger), and the protec- tion of our environment.
6 SAFETY Safety Decals and Locations W arning decals have been placed o n the A TV for yo ur protection. Read and follow the instructions of the de cals on the A TV carefully . If any of the decals depicted in this manual dif fer from the d ecals on your A TV , always read and follow the instruc tions of the decals on the A TV .
7 SAFETY Safety Decals and Locations General Warning WARNING Improper A TV use can result in SEVERE INJURY or DEA TH AL WA YS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERA TOR AND P ASSENGER NE.
8 SAFETY Safety Decals and Locations P assenger Safety Warning WARNING P ASSENGER SAFETY T o reduce the risk of SEVERE INJURY or DEA TH NEVER CARRY A P ASSENGER UNDER AGE 12 NEVER CARRY MORE THAN ONE P ASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly pl ant feet on footrests and securely grasp hand holds.
9 SAFETY Safety Decals and Locations Rack W arning WARNING DO NOT TOW FROM RACK OR BUMPER. V ehicle da mage or tipover may result causing severe injury or death. T ow only from tow hooks or hitch. Maximum Rack Loads: F ront 90 lbs. (41 kg) Rear 180 lbs.
10 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort and to redu ce the chance of in jury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
11 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE ) bearing markings such as VESC 8, V -8, Z87.
12 SAFETY Rider Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. Never allow anyone under 12 years of age to ride as a passenger on this 2-up A TV . WAR N I NG F ailure to follow the warnings contained in this manual can result in severe injury or death.
13 SAFETY Rider Safety Safety T raining A TV safety t raining is a top priority for Polaris. Wh en you purchased your new A TV , your dealer instructed you on the autho rized A TV RiderCourse sm ava ilable to you and you r e ligible family members. This training is included in the purchase price of your A TV .
14 SAFETY Rider Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safe ty alert symbol , on your vehicle or in this manual, ale rts you to the potential for injury .
15 SAFETY Rider Safety • Read this manual and all labels careful ly , and follow the operating procedures described. • Never operate an A TV without prop er instruction. T ake a training course. Purchasers of a new Polari s A TV and their eligible family members are entitled to take the A TV Rider Course sm .
16 SAFETY Rider Safety • Never operate an A TV without wearin g an approved helmet that fits properly . Always wear eye protection (goggles or face sh ield), gloves, boots, a long-sleeved shirt or ja cket, and long pants. A passenger's helmet should have a rigid chin guard.
17 SAFETY Rider Safety • Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a hill . Shift your weight uphill. Never go down a hill at high speed. A void going down a hill at an angle, which woul d cause t he vehicle to lean sharply to one side.
18 SAFETY Rider Safety • Always check for obstacles or people behind the A TV before operat- ing in reverse. Be aware that a passenger can obstruct your view . When it's safe to proceed in reverse, move slowly and avoi d turning at sharp angles.
19 SAFETY Rider Safety Equipment Modifications W e are concerned for the safety of our customers and for the general public. Therefore, we strongly reco mmend that consumers do not install on a Polaris A TV any equipment that may increase the speed or power of the vehicle, or make any other m odifications to the vehicle for these purposes.
20 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Operating this A TV wi thout proper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if th e operator does not know how to operate the A TV properly in different situations and on different types of terrain.
21 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Operating with more than one passenger . WHA T CAN HAPPEN Passengers affect balance and steering and increase the risk of losing control, which can result in severe injury or death. HOW TO A VOID THE HAZARD Never operate the 2-up A TV with more than one passenger .
22 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Operating this A TV on publi c streets, roads or highways. WHA T CAN HAPPEN The A TV could collide with another vehicle. HOW TO A VOID THE HAZARD Never operate the A TV on any public street, road or highway , including dirt and gravel roads.
23 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Operating the A TV after consuming alcoh ol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drug s could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.
24 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Attempting jumps and other stunts. WHA T CAN HAPPEN Attempting stunts increases the chan ce of an accident, including an overturn. HOW TO A VOID THE HAZARD Never attempt jumps or other stunts. Avoid exhibition driving.
25 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHA T CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the A TV .
26 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD F ailure to use extra caution when operating on excessive ly rough, slippery or loose terrain. WHA T CAN HAPPEN Operating on exce ssively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.
27 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Operating on exce ssively steep hills. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZARD Never operate on hills too steep for the A TV or for you r abilities. Never operate the A TV on hills steeper tha n 15 degrees.
28 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD T raveling downhill imprope rly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of con trol or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual.
29 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHA T CAN HAPPEN Improperly crossing or turning on hills could cause loss of con trol or overturn .
30 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZARD Maintain steady speed wh en climbing a hill. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
31 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Improperly operating over obstacles. WHA T CAN HAPPEN Operating over ob stacles could caus e loss of control or overturn. HOW TO A VOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over la rge obstacles such as rocks and fallen trees when possible.
32 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Operating the A TV through dee p or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or o verturn. HOW TO A VOID THE HAZARD Avoid operating the A TV through dee p or fast-flowing water .
33 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Operating this A T V with improper tires, or with improper or uneven tire pressure. WHA T CAN HAPPEN Use of improper tires, or operation of the A TV with improp er or uneven tire pressure, could cause loss of control or accident.
34 SAFETY Rider Safety WAR N I NG POTENTIAL HAZARD Overloading the A TV or carrying/towing cargo improperly . WHA T CAN HAPPEN Overloading and towing can caus e changes in vehicle handlin g, which could lead to loss of control or an accident. HOW TO A VOID THE HAZARD Never exceed the stated load capacity for this A TV .
35 SAFETY Rider Safety WAR N I NG Operating a dama ged A TV ca n result in an accident with seri ous injury or death. After any o verturn or accident , have a qualified se rvice dealer inspect the entire machine for possible damage, includin g (but not limited to) brakes, throttle and st eering systems.
36 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limi ter sy s t em .T o gain additional power while backing, depress the override switch. NOTE: The override switch al so allows activa tion of 4X4 in reverse, if the 4X4 switch is on.
37 FEA TURES AND CONTROLS Switches Differential Switch Use the differential switch to lock and unlock the rear dif ferential. Locked Differential: Operate the vehicle with the switch in the locked position in most conditions.
38 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle move- ment are controlled by pressing the throttle lever . The throttle lever is spring loaded.
39 FEA TURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the fro nt an d rear brakes. These brakes are hydraulically activ ated disc type brakes tha t are activat ed by only one lever . Always test brake lever travel and master cylinder fluid level before riding.
40 FEA TURES AND CONTROLS Master Cylinde r/Brake Fluid Check the brake fluid in the master cylinder before each ride. The fluid level can be see n through an indicator window on the to p of the master cylinder . This eye will appear dark when the fluid level is full.
41 FEA TURES AND CONTROLS Pa r k i n g B r a k e Locking the P arking Brake 1. Place the transmission in PA R K . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock.
42 FEA TURES AND CONTROLS Auxiliary F oot Brake The auxili ary brake syst em is intend ed to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. NOTE: Since this is a rear brake only , it will not be as effective as the all-wheel single lever system.
43 FEA TURES AND CONTROLS Automatic T ransmission 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 Whenever the A TV is left unattended , always place the transmission in P ARK and lock the parking brake.
44 FEA TURES AND CONTROLS Recoil Starter (500 EFI) If the battery is too weak to start the engine, use the recoil starter . Follow the starting procedures on page 59, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope han- dle tightly .
45 FEA TURES AND CONTROLS All Wheel Drive System The All Whee l Drive syst em is controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.
46 FEA TURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is movin g. Initially , the vehicle's electronic sy stem will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remai ns enabled until the 4X4 switch is turned off.
47 FEA TURES AND CONTROLS Active Descent Cont rol (ADC) System The ADC system allows engine brak ing to all four wheels when the vehicle descends a hill or incline.
48 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmis sion.
49 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 2.
50 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle thro ug h the mode options. Th e reverse override button is also the MODE button. See page 36. NOTE: The transmission cannot be in reverse when using this feature.
51 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when th e gauge is in the diagnostic mode. T o exit the diagnostic mode, turn th e key switch off and o n. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode.
52 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Screen V iew this screen to check battery voltage level. T a chometer Screen V iew the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge ind icates whether or not current is flowing through the all wheel drive coil.
53 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval T o enable or disable the service interval: 1.
54 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only . Please see your Polaris dealer fo r all major repairs. See page 55 for Blink Co des and Failu re Descriptions.
55 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code F ailure Description 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor Hi.
56 OPERA TION F uel Safety WAR N I NG Gasoline is h ighly flammable and explosive under certain conditions. • Always exercise extreme caution wheneve r handling gasoline. • Always refuel with the engi ne stopped, and outdoors or in a well ventilated area.
57 OPERA TION Break-In P eriod The break-in period for yo ur new Polaris A TV is the first ten hours of operation, or the time it takes to use the first two full ta nks of gasoline. No single action on your part is as important as following the proce- dures for a proper break-in.
58 OPERA TION Pre-Ride Checklist WAR N I NG If a proper inspection is not done befor e each use, severe injury or death could result. Always inspect the vehicl e before each use to ensure it's in proper operating condition.
59 OPERA TION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Lock the parking brake. NOTE: The starter interl ock will prevent the engine from starting if the trans- mission is in gear and the brake is not enga ged.
60 OPERA TION Hauling Cargo WAR N I NG Overloading the vehicle or carryi ng or towing cargo improperly can alter vehicle handling and may cause loss of co ntrol or brake instability . Always follow these p recautions when haulin g cargo: Never exceed the stated load capacity for this vehicle.
61 OPERA TION Hauling Cargo Y our A TV has been designed to carry or tow a certain amount of load. Always re ad and understand the load d istri- bution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decals.
62 OPERA TION Driving Procedures 1. W ear protective ridin g gear . See page 10. 2. Perform the pre-ride inspection. See page 58. 3. Place the transmission in P ARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on th e footrests and both hands on the handlebars.
63 OPERA TION T urning the V ehicle Both rear wheels drive equally at all times (except when operating in 2X4 mode with the differential unlocked). This means that the outside wheel must travel a greater di stance than th e inside wheel when turning, and the inside tire must slip traction slightly .
64 OPERA TION Driving with a P assenger 1. Make sure the passenger is at le ast 12 years of age and is tall enough to comfortably reach the footrests and grab handles. 2. Make sure the passenger is wearin g appropriate riding gear, includ- ing an approved helmet with a rigid chin guard.
65 OPERA TION Driving with a P assenger 10. Ride to the ability of your passeng er , instead of to your own ability . A void unexpecte d or aggressive maneuvers that could cause a pas- senger to fall from the vehicle. 1 1. Do not cross a hillside with a passenger on board.
66 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Slow down when en tering slippery areas. 2. Engage 4X4 before wheels begin to lose trac- tion.
67 OPERA TION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4 X4 before ascending or descending a hill. See page 47. 2. Drive straight uphill. 3. A void steep hills (15 ° maximum). 4. Keep both feet on the footrests.
68 OPERA TION Driving on a Sidehill (Sidehilling) Sidehilling can be dangerou s and should be avoided if at all possible. If you encounter a situation where si dehilling is necessary , follow these precautions: 1. Slow down. 2. If operating in 2X4 mode, make sure the differential i s locked.
69 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4 X4 before ascending or descending a hill. See page 47. 2. Always descend a hill with the tr ansmission in forward gear . Do not descend a hill with the tr ansmission in neutral.
70 OPERA TION T urning Around on a Hill (K - T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.
71 OPERA TION T urning Around on a Hill (K - T urn) 1. S top and lock the parking brake wh ile keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4 X4 before ascending or descending a hill. See page 47. 3. Leave the transmission in forward and shut off the engine.
72 OPERA TION Driving Through W ater Y our A TV can operate through wa ter with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through wat er: 1. Determine water depths and current before crossing.
73 OPERA TION Driving Through W ater After running the vehicle in water , it's critical to have it serviced as out- lined in the maintenance chart. See page 79. The following areas need special attention: engine oil, transm ission oil, demand d rive fluid and all grease fittings.
74 OPERA TION Driving Over Obstacles 1. Be aler t! Look ahead an d learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hang- ing branches. 2. A void operating over large obstacles such as rocks and fallen trees when possible.
75 OPERA TION P arking on an Incline A void parking on an incline if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parking brake. 4. Always block the rear wheels on the do wnhill side.
76 OPERA TION Driving in Reverse WAR N I NG F ailure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. W hen it's safe to procee d, back slowly .
77 OPERA TION Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view . 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the bra kes lightly for stopping.
78 EMIS SION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.
79 MAINTENANCE P eriodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main ten a nc e ch art.
80 MAINTENANCE P eriodic Maintenance Chart Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warrant y but may af fect emissions.
81 MAINTENANCE P eriodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Air filter , main element - Weekly - Inspect; replace as needed Recoi.
82 MAINTENANCE P eriodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
83 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart be ginning on page 79. Items not listed in the chart should be lubr icated at the General Lubrication interval.
84 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil.
85 MAINTENANCE Engine Oil Oil Level (500 EFI) Access the oil dipstick and fill tube from the left side of the A TV . NOTE: A rising oil level between checks in cool weather driving can indicate conta minants such as gas or moisture col- lecting in the cr ankcase.
86 MAINTENANCE Engine Oil Oil Level (800 EFI) Access the oil dipstick and fill tube from the left side of the A TV . 1. Position the vehicle on a level surface. 2. Lift the lever lock to remove the dipstick. W ipe it dry with a clean cloth. 3. Reinstall the dipstick com- pletely , but do not lock it.
87 MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginn ing on page 79. 1. Position the vehicle on a level surface. 2. Star t the engine. Allow it to idle for two to three minut es.
88 MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) 12. Place shop towels beneath the oil filter . Using an oil filter wrench, turn the filter counterclockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine.
89 MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.
90 MAINTENANCE Engine Oil Oil and Filter Change (800 EFI) Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 79. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface.
91 MAINTENANCE Engine Oil Oil and Filter Change (800 EFI) 9. Place shop towels beneath the oil filter . Using an oil filter wrench (available from your Polaris dealer), turn th e filter counter- clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
92 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 79. Maintain the oil level at the bottom of the fill pl ug hole threads. W e recomme nd the use of Polaris Premium AGL Synthetic Gearcase Lubrica nt.
93 MAINTENANCE T ransmission Oil T ransmission Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allo w the oil to drain completely . 4. Clean and reinstall the drain plug. T orque to 20 -25 ft. lbs.
94 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Level 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommend ed demand driv e fluid as needed to bring the level to the bottom of the fill hole threads.
95 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Level 1. Open the front box cover and pull open the access door . 2. V iew the fluid level in the reservoir . If the level is below the minimum mark, remove the cap and add the recommended fluid.
96 MAINTENANCE Cooling System The engine coolant level is controll ed, or maintained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
97 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair .
98 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar . These brakes are self- adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drops.
99 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. 1. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahead position.
100 MAINTENANCE Steering Assembly The steering assembly o f the A TV should be check ed p eriodically for loose nuts and bolts. If loose nu ts and bolts are found, see your Polaris dealer for service before operati ng the vehicl e. Side P anel Removal 1.
101 MAINTENANCE Tires Refer to the specifications section begin ning on page 138 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. F ront Wheel Hub Tightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operations.
102 MAINTENANCE Tires Wheel Installation 1. Place the transmission in P ARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing t oward forward rotation. 4. Install the wheel nuts and finger-tighten them.
103 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre-filter from the main filter . W ash the pre- filter in soapy water , then rinse and let dry .
104 MAINTENANCE Breather Filter /Hose (500 EFI) The breather filter is on the hose that runs between the engine and air box. 1. Remove the left side panel. See page 100. 2. Remove the hose clamps from t he fil- ter and pull the filter out of the hoses.
105 MAINTENANCE F use Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. NOTE: Spare fuses are provided in a compartment on the top of the access door . 1. Open the front box cov er and pull open the access door .
106 MAINTENANCE Lights When servicing a halog en lamp, don't 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. Headlight Lamp Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod.
107 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall .
108 MAINTENANCE Lights Headlight Housin g Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconn ect the speedometer harnes ses from the speedometer .
109 MAINTENANCE Lights Lower Headlamp Replacement 1. T urn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headlamp . 3. Reinstall the harness assembly into the headlight assembly .
110 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications sect ion beg inn ing on pa ge 1 38 for the recom- mended spark plug t ype and gap for yo ur vehicle. T orque spark plugs to specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operation.
111 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Pl ug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service.
112 MAINTENANCE V ehicle Immersion 1. If it's impossible to take your A TV to a dealer before starting it, fol- low the steps outlined below . 2. Move the A TV to dry land or at the very least, to water below the footrests. 3. Check the air box. If water is present, dry the air bo x and replace the filter with a new filter .
113 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur ge accumulated carbon from the exhaus t pipe/muffler . 1. Remove the arrestor clean-out plug from the bot tom of the muffler . 2. Place the transmission in PA R K . 3. Star t the engine.
114 MAINTENANCE PVT System WAR N I NG F ailure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failu re may occur at a high speed.
115 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt.
116 MAINTENANCE PVT System When T o Use Low Range and High Range PVT Drying There may be some instances when wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface.
117 MAINTENANCE Battery Y our A TV may have either a sealed battery , which requires little mainte- nance, or a conventional battery . A sealed battery can be identified by its flat covers on the top of the battery . A conventional battery has six filler caps on the top of the battery .
118 MAINTENANCE Battery Battery Removal 1. Loosen the battery hol d-down bolt. 2. Remove the battery cover . 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last.
119 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructio ns on page 121 before installing the battery .
120 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three mo nths or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e an d recharge as needed to mainta in a full char ge.
121 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electroly t e during charging. See page 1 18. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating.
122 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge V oltage Action Charge Time (Using constant cu rrent charger @ standard amps specifie d on top of batter y) 100% 12.
123 MAINTENANCE Cleaning and Storage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water .
124 MAINTENANCE Cleaning and Storage W ashing the V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution.
125 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years.
126 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 123. Stabilize the F uel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel T r eatment or Polaris Fuel St abilizer .
127 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as reco mmended in the Periodic Maintenance Char t beginning on page 79.
128 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lu bricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 79. Battery Storage See pages 120-121 for storage and charging procedures.
129 MAINTENANCE T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in PA R K . 3. Lock the parking brake. 4. Secure the fuel cap and oil cap. 5. Always tie the frame of the A TV to the transporting unit securely with suitable straps or rope.
130 ADJUSTMENTS Camber and Caster The camber and caster are non-adjust- able. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer .
131 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. 1. Remove the upp er headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height . NOTE: Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.
132 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your Polaris dealer for adjustment. Throttle Cable F reeplay Adjust throttle cable freeplay at the handlebar . 1.
133 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 70).
134 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , F ails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge th e battery to 12.
135 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended fuel Incorrect ignition timin.
136 TROUBLESHOOTING Engine Stops or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fue.
137 POL A RIS PRODUCTS Pa rt Number Description Engine Lubr icant 2870791 Fo gging Oil (12 oz. Aero sol) 2876244 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (gal.) Gearcase / T ransmission L ubricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt.
138 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 500 T ouring Maximum W eight Capacity 600 lbs. (272 kg) (includes operator , passen- ger , cargo, accessories) Dry W eight 7 70 lbs. (349 kg) (base model) Front Rack/Storage Box Capacity 90 lbs.
139 SPECIFICA TIONS Clutching (EBS Models) NOTE: *EBS models require no helix/spring adjustment Sportsman 500 T ouring T ransmission Automatic EBS (Engine Braking System) with E-Z Shift H/ L/N/R/P Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.
140 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 800 T ouring Maximum W eight Capacity 6 00 lbs. (272 kg) (includes operator , passen- ger , cargo, accessories) Dry W eight 7 95 lbs. (361 kg) (base model) Front Rack/Storage Box Capacity 90 lbs.
141 SPECIFICA TIONS Clutching (EBS Models) NOTE: *EBS models require no helix/spring adjustment Sportsman 800 T ouring T ransmission Automatic EBS (Engine Braking System) with E-Z Shift H/ L/N/R/P Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.
142 W ARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s.
143 WA RRANTY WARRANTY COVERAGE AND EX CLUSIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris limi ted warranty excludes any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling.
144 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AN D FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY .
145 WA RRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries.
146 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, a ll warranty coverage will be denied.
147 WA RRANTY U.S.A. EP A Emissions Limited Warranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limited warranty is in addition to the Polaris st andard limited warrant y for this vehicle.
148 MAINTENANCE L OG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed.
149 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COM MENTS.
An important point after buying a device Polaris 500 EFI Touring (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris 500 EFI Touring yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris 500 EFI Touring - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 500 EFI Touring you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 500 EFI Touring will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 500 EFI Touring, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris 500 EFI Touring.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 500 EFI Touring. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 500 EFI Touring along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
