2005 POLARIS SPORTSMAN 500 OWNERS MANUAL PDF

Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop proce- dures in order to perform the work safely and correctly. The technician should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor- tance.

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Quick Links. See also: Handbook , Service Manual. Table of Contents. Pantone C. Read this manual carefully. It contains important safety information. Operation is prohibited for those under 16 years of age. Polaris industries all-terrain vehicles owner's manual pages. Polaris industries all-terrain vehicle owner's manual pages.

Polaris industries all terrain vehicle owner's manual pages. This is an adult vehicle only. 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 for assistance.

Copyright 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 publi- cation. Page 7: Table Of Contents Troubleshooting Page 8: Introduction The following signal words and symbols appear throughout this manual and on your vehicle.

Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard.

Page 9 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. Page 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. Page Safety You should review this information on a regular basis. Page 12 Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Department of Transportation DOT label. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield.

Operator and passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield. Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. NOTE: A special technique is required when braking while traveling down- hill. Do not operate on excessively rough, slippery or loose terrain.

Always follow proper operating procedures as outlined in this manual. See page Before shifting into reverse gear, always check for obstacles or people behind the ATV. Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth see page 55 Never operate the ATV on a frozen body of water. Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street.

Page Safety Decals And Locations If an informational or graphic label becomes illegible or comes off, con- tact 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. Loss of control can result in severe injury or death. To prevent serious injury, do not operate vehicle with guard removed.

Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death. To gain additional wheel speed while backing, release the throttle and depress the override button. The engine will not start or run when the switch is off.

Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights. Page 30 The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. If the Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes.

Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. Place the transmission in PARK. Squeeze and release the brake lever two or three times, then squeeze and hold. Push the parking brake lock forward to engage the lock. Release the brake lever. Never back down a hill. Use caution when applying the auxiliary brake.

Do not aggressively apply the auxiliary brake when going forward. Refer to the engine starting procedure on page 46 for correct choke and throttle settings during start- ing. Fuel Valve The fuel valve is located under the front storage box cover. OFF: For vehicle storage and when transporting. When the engine is idling, move the lever to the desired gear.

When the switch is on 2X4, the ATV is in two-wheel drive at all times. 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. Gear Indicator - This The reverse override button is also the MODE button. The transmission cannot be in reverse when using this feature. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode: 1. Tachometer Screen View the tachometer to check engine speed. Enter the diagnostic mode. Toggle to the service interval screen. Toggle to the screen that displays either kilometers KM or miles MP. Page Operation Break-In Period The break-in period for your new Polaris ATV 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 is as important as following the proce- dures for a proper break-in. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Check the oil level on the dipstick.

Add oil if neces- sary to maintain the level between the safe and add marks. Complete the recommended safety training before operating this vehicle.

See page 7. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle. Page Trail Etiquette Respect the environment in which you ride.

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