Polaris Sportsman-500-EFI Owners Manual 2009

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342- 3764 for assistance. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

1 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 We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced. For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period. We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

2 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2008 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 discrep- ancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2009 Sportsman 500 Touring/Sportsman 800 Touring Owner’s Manual P/N 9921788

3 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Emission Control Systems . . . . . . . . . . . . . . . 69 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 123 Polaris Products . . . . . . . . . . . . . . . . . . . . . . . 127 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 128 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 138 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

4 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. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury. CAUTION A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE A NOTICE indicates a situation that may result in property damage. The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard. The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

5 INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. • Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a Polaris ATV. Keep this manual with the ATV. • Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse sm . Contact ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCourse sm . • This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. • Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course. WARNING

6 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. Vehicle Model Number: ___________________________________________________ Frame VIN: ____________________________________________________________ Engine Serial Number: ___________________________________________________ Key Number: ___________________________________________________________ #### VIN Engine Serial Number Key Number 500 800

7 SAFETY Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV Rider- Course sm available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse sm . You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis. If you purchased a used Polaris ATV, you can take the ATV RiderCours- e sm by calling ATV Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training. A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342- 3764.

Polaris Sportsman-500-EFI Owners Manual 2009

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