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2012 FOREST 500.fm

1. 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 oper 40 Tires Inspect condition and pressure 90 Wheels fasteners Inspect ensure fastener tightness 90 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels an Throttle Ensure proper operation 96 Indicator lights switches Ensure proper operation 34 Engine stop switch Ensure proper operation 35 Mirrors Adjust for best side rear vision 37 Air filter pre filter Inspect clean 92 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply POLARIS 95 dielectric grease when lamp is replaced Brake light tail lamp Check operation apply POLARIS 96 dielectric grease when lamp is replaced Riding gear Wear approved helmet goggles and 16 protective clothing Winch Inspect cable and switch 57 58 53 OPERATION Starting the Engine A 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
2. 77 Engine Oil 70 Transmission 75 Fluid Recommendations Demand Drive 77 Engime z2 2i tek elec 69 Transmission 75 F Foot Brake 04 38 Footwell Removal 88 Front Gearcase 77 78 Fuel Filter 000 4 Fuel Safety cess pa steele xe ee 51 Fuel Tank Cap 0 41 Fuel Valys 355 oe dez 41 Fuse Replacement 97 G Gear Selector tensi sn cet ies 42 Gloves 3 oar uo eee sui 17 H Handlebar Adjustment 87 Hauling Cargo 32 33 Hazard Warning Switch 36 Headlight Beam Adjustment 94 Headlight Lamp 95 Headlight Switch 35 He linet imc apes 16 High Beam Switch Momentary 34 High Range Use 105 Horn Switch 0 36 I J K Idle RPM Adjustment 79 Immersion 100 101 Instrument Cluster 45 50 Jetting Chart 121 Key Switch 0 35 K Tum 3s oe Ses Ss Seeks 26 27 L Light Switch 34 Lights e echt seade 94 96 Front Turn Signal 96 Headlight Beam Adjustment 94 Headlight Lamp 95 Momentary High Beam Switch 34 Position Light Lamp 95 Rear Turn Signal 96 Taillight 12 ted ae as 96 Low Range Use 105 Lubrication Guide
3. 88 Sidehilling 24 Signal Words 2 4 Spark Arrester 102 103 Spark Arrester Requirements 62 Spark Plugs 98 99 Specifications 120 121 Spring Adjustment Rear 87 Starting the Engine 54 55 Steering Assembly 87 Steering Lock 40 Stop Switch 04 35 Storage sees 113 118 Switches cece ee 34 36 AWD Switch 34 Engine Stop Switch 35 Hazard Warning Switch 36 Headlight Switch 35 Horn Switch 36 Main Key Switch 35 Mode Reverse Override Switch 34 Momentary High Beam Switch 34 Turn Signal Switch 36 Winch Switch 34 136 T Taillight 0 0000 96 Throttle Cable Freeplay 89 Throttle Lever 0 37 Tire Tread Depth 90 Tires vvv os shes ers Bares acer 90 91 Front Wheel Hub Tightening 90 Tread Depth 90 Wheel Installation 91 Wheel Nut Torque 90 Wheel Removal 91 Toe Alignment 86 Towing a Disabled Vehicle 119 Towing Loads 33 Training Safety 5 Transmission Oil 75 76 Transporting the Vehicle 119 Turn Signal Lamp Rear 96 Turn Signal Replacement Front 96 Turn Sign
4. 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 emer gency situation A WARNING Never connect DC powered winches to AC current Motor damage or fatal shock may occur A DANGER Stand clear of the cable and load during winching Keep helpers and spectators at a safe distance If a cable pulls loose or breaks under the load it can lash back with dangerous force 3 Beware of the danger zone The danger zone is the area of the rotating wire cable drum the fairlead if fitted P the cable the hook and the ao gt motor Before placing hands __ e du N in or near the danger zone prx pr first relieve tension on load i then disconnect the control switch 4 Ifyou are within four feet of the winch do not hold the cable and the remote 1f equipped at the same time 56 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 re spooled under a minimum of a 100 Ib 45 4 kg load before use Failure to do this will result in cable damage Inspect all cable before use Mashed pinched frayed or kinked areas severely reduce the load carrying capability Replace dam aged cable promptly Prevent kinks before they occur Am A This is a start of a kink Straighten the cable before using it
5. 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil 95 I 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil 3 8 1 Gearcase Transmission Lubricants 2878068 AGL PLUS Transmission Fluid 95 I 2878069 AGL PLUS Transmission Fluid 3 8 I 2877922 Demand Drive Plus Fluid 95 I 2877923 Demand Drive Plus Fluid 3 8 I 2870465 Pump for 3 8 liter jug 2871654 Premium Demand Drive Hub Fluid 237 ml 2872277 Premium Demand Drive Hub Fluid 9 5 I Coolant 2871323 60 40 Coolant 3 8 1 2871534 60 40 Coolant 95 1 Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 89 ml cartridge 2871423 Premium All Season Grease 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 89 ml 2871551 Premium U Joint Lube 414 ml 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2872893 Engine Degreaser 2871956 Loctite 565 Thread Sealant 2871076 POLARIS Battery Tender Charger 122 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range Starting out going up a steep incline Use low range or turn around using the K turn see page 26 Driving at low RPM or speed 5 11 km h Drive at a higher speed or use low range more frequently Insufficient warm up at l
6. MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 1200 LBS 546 kg Read Owner s Manual for more detailed loading information A Clutch Cover Alert NO STEP A Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rack Loads Front 90 Ibs 41 kg Rear 180 Ibs 82 kg A Reverse Override Alert Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in AWD See Owner s Manual 15 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury Helmet Long Sleeves Gloves Long Pants Helmet Always wear a helmet that meets or exceeds established safety stan dards 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 The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label 16 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever ridi
7. 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 Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient opera tion Optional jets available from your POLARIS dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your POLARIS dealer for more information about jetting the ATV for conditions in your area Pilot screws are sealed with metal plugs and are serviceable only by POLARIS dealers Carburetor Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carbu retor can be adjusted 1 Start the engine and allow it to warm up for approximately five minutes 2 Place the transmission in gear W Lock the parking brake 4 Turn the screw in clockwise to raise RPM Turn the screw out counter clockwise to lower RPM 79 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
8. 68 M Maintenance Chart 63 67 MITFOISr inue up cse Soke eee 37 Mode Switch 005 34 Modifications 0005 5 N Noise Emission Control System 62 0 Oil Demand Drive TI T8 Engine Oil 69 74 Transmission 75 16 Oil Change Demand Drive 78 Engine Oil ee ak uus 72 Transmission 76 Oil Level Demand Drive 77 Engine Oil 70 Transmission 75 Oil Pump Priming 74 Oil Recommendations Demand Drive TI Enges A haa Ale 69 Transmission 75 Operator Safety 7 13 Override Switch 34 P Parking Brake 39 Parking on an Incline 30 Periodic Maintenance Chart 63 67 Polaris Product List 122 Polishing the Vehicle 114 Position Light Lamp 95 Pre Ride Checklist 53 PVT Break In 223 bees 52 PVT Drying 62 PVT System 104 105 135 INDEX R Recoil Housing 106 Recoil Starter 43 Reverse Operation 31 Reverse Override Switch 34 Rider Information Center 46 50 Riding Gear 16 17 S Safety Labels 14 15 Safety Training 5 Service Interval Programming 50 severe Users oats o Ex 63 Side Panel Removal
9. B The cable was pulled and the loop has tightened to a kink The cable is now permanently damaged and T should not be used B E dd C Theresult of kinking is that each R strand pulls a different amount of load causing the strands under the oces ine load capacity ofie t reduces entire cable oe mR Before re spooling remove all load from the cable Hold the han dlebar switch lead in one hand and the cable in the other Move away from the vehicle as far as the switch will allow Activate the switch walk in several feet of cable then release the switch Repeat this process until the re spooling is complete CAUTION To avoid injury always release the switch before your hand comes within four feet of the fairlead the physical opening through which the cable passes 5 6 Be sure the cable is distributed evenly and tightly on the drum A loosely wound drum may allow the cable to work its way down into the layers of cable on the drum and become wedged Do not grease or oil the cable Doing so causes dirt contamination that will reduce the life of the cable 57 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 N gloves on When handling the hook C52 always use a handsaver Never place SZ fingers into the hook Placing fingers in the hook could result in injury A WARNING In
10. Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience 25 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 1 Stop the vehicle Keep your weight uphill 2 Lock the hydraulic parking brake 3 Leave the transmission in forward gear Turn the engine off 4 Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill 5 Stay uphill of the vehicle and turn the handlebars full left 6 Squeeze the brake lever to release the parking brake 7 Slowly release the brake lever and allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 26 SAFETY Driving Safely Turning Around on a Hill K Turn 8 Lock the hydraulic parking brake 9 Remount from the uphill side Keep your weight uphill 10 Apply the foot brake 11 With the transmission still in forward start the engine 12 Squeeze and release the brake lever to release the parking brake 13 Release the foot brake and drive slowly downhill Control speed with either the hand or foot brake until the vehicle is on level ground A Always follow the procedures outlined in this manual for climbing hills See page 22 A Always follow the procedures outlined in this manu
11. 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 Start the engine Turn the headlight switch to high beam 5 Observe the headlight aim on the wall The most intense part of the headlight beam should be 5 cm below the mark on the wall 6 Tighten or loosen the lower headlight screws to adjust the beam 94 MAINTENANCE Lights A 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 Hold the plastic part of the lamp 1 Place the transmission in PARK zem Light im 2 Reach under the front bumper area to locate the lighting connectors cT 3 Parking Light Lamp Disconnect the harness connector Turn the socket counter clockwise 1 8 turn and remove the lamp assembly Pull the lamp straight out to remove it from the socket Headlamp 4 Headlight Lamp Disconnect the harness connector Remove the rubber cover from the back of the headlight Pres
12. rearward to remove it Footwell Removal 1 Remove the four screws on the bottom of the footwell 2 Usea flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell 88 Throttle Cable Freeplay MAINTENANCE Adjust throttle cable freeplay at the handlebar 1 Locate the throttle cable adjuster at the handlebar 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 6 3 2 mm of freeplay is achieved at the thumb lever Move the throt tle lever back and forth while adjusting 5 Tighten the lock nut 6 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position b Boot J Lock Nut Adjuster lt lt WARNING Engine RPM should not increase when steering is turned full left or right Readjust cable freeplay if this occurs 89 MAINTENANCE Tires A 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 th
13. 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 97 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 120 for the recom mended 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 Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 99 Normal Spark Plug The normal insulator tip is tan or brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetor adjust ments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect carbu retor adju
14. Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 37 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 pU ake brake reduce brake pressure 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 If the rear wheels begin to skid or slide while using the brake reduce lever pressure A Aggressively applying the brakes when backing down a hill may cause rear tipover Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control Read this owner s manual and understand the operation of all brake systems on this vehicle Always use caution whenever applying the brakes 38 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake l 2 Place the transmission in PARK Squeeze the brake lever toward the handlebar Push the parking brake lock forward to engage the lock Release the brake lever To release the parking brake lock squeeze and release the brake lever A Operating the vehicle while the parking
15. The gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD This screen is for informa tional purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance See page 50 The service interval is programmed at 50 hours at the factory 49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval l 2 3 Enter the diagnostic mode Toggle to the service interval screen 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 l 2 3 Enter the diagnostic mode Toggle to the service interval screen Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button Press and release the mode button once to advance t
16. 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 Excessive use of the choke can cause the spark plug to become wet fouled 5 Ifthe engine is cold pull the choke knob out until it stops If the knob doesn t stay where positioned increase the tension by rotating the tension adjusting nut clockwise Tip The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually Ey depending on how much choke is needed Adjusting Nut for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 6 Move the engine stop switch to RUN 54 OPERATION Starting the Engine 7 Donotpress 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 Ifthe engine does not start release the starter and wait five seconds 9 Repeat steps 7 and 8 until the engine starts A Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating 10 If a warm engine has cooled to a point where it does not readily star
17. is ipid OMM A MEM MN traction the demand drive unit automatically disengages 2X4 When the 2X4 switch is on the vehicle is in two wheel drive at all times and the dif ferential is locked 44 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 addi tional information Speedometer Needle Speedometer Rider Information P amp LARIS Center A High water pressure may damage vehicle components Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 45 FEATURES 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 5 seconds at start up If the instrument cluster fails to illuminate a battery over
18. left or right to activate the corresponding turn sig nal light The indicator on the pod will also flash Return the toggle to the center posi tion to end the signal Horn Switch box Press the horn switch to sound the horn Hazard Warning Switch A Push the hazard warning switch to cause all turn signal lights to flash simulta neously Use this feature to alert others of an emergency or other situation requiring caution 36 f Hazard Switch Turn Signal Switch Horn Switch FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers Always check and adjust the mirrors before driving the vehicle Throttle Lever A 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 Contact your dealer for repair if throttle problems arise Electronic Throttle Control Press the throttle lever to increase engine speed and vehicle movement aM Release the lever to reduce f noes engine speed and vehicle A gt movement vun Electronic Throttle Control ETC ETC causes the engine to stop if the throttle cable sticks in an open posi tion when the operator releases the throttle lever A The Electronic Throttle
19. or tap water into a conventional battery 107 MAINTENANCE Battery Battery Removal 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 BO ONS prs Oo Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 108 MAINTENANCE Battery Battery Installation l 2 3 Ensure that the battery 1s fully charged Place the battery in the battery holder With conventional batteries install the battery vent tube sealed bat teries 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 A Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 19 99 m UNA On conventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten
20. s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation 47 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 move ment 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 Release the switch as soon as the display is activated 5 Usethe mode button to toggle through the diagnostic screens 48 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
21. the engine 29 SAFETY Driving Safely Parking on an Incline Avoid parking on an incline If it s unavoidable follow these precau tions 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 30 SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse Avoid backing downhill Always check for obstacles or people behind the vehicle before backing Drive slowly Apply the foot brake lightly for stopping Avoid turning at sharp angles Do not use the override switch unless additional power is required for vehicle movement Use with caution Reverse speed is greatly increased when the override switch is used Do not operate at full throttle Apply just enough throttle to maintain the desired speed A Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage A Always follow the procedures outlined in this manual for driving in reverse 31 SAFETY D riving Safely Hauling Cargo A Overloading the vehicle or carrying or towing cargo improperly can alter vehicle ha ndling and may cause loss of control or brake instability Always follow these precautions when hauling cargo 32 Read and understand the load distribution warnings listed on the vehicle warning labels Ne
22. the terrain Use extra caution W Never operate over large obstacles 4 Avoid hazards such as logs rocks and low branches A Always follow the procedures outlined in this manual for operating over obstacles 21 SAFETY Driving Safely Driving Uphill 25 Maximum Whenever traveling uphill follow these precautions Avoid steep hills 25 maximum Check the terrain carefully Avoid hills with excessively slippery or loose surfaces Shift your weight uphill Drive straight uphill Keep your feet on the footrests Drive at a steady rate of speed to avoid stalling Be alert Be prepared to take emergency action This may include dismounting quickly GO n Qv Uv Rw PO 9 Never open the throttle suddenly or make sudden gear changes 10 Never go over the top of a hill at high speed 22 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 A Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 25 A Always follow the procedures outlined i
23. 0 12M 1600 Inspect pipe Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Kilometers 5 Spark plug 100 12M 1600 Inspect replace as needed gt Wiring 100 12M 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc E Clutches drive 100 12M 1600 Inspect clean replace worn and driven parts E Front wheel 100 12M 1600 Inspect replace as needed bearings E Brake fluid 200 24M 3200 Change every two years Spark arrester 300 36M 4800 Clean out E Toe adjustment Inspect periodically adjust when parts are replaced E Brakes Inspect daily adjust as needed Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service W Have an authorized POLARIS dealer perform these services 67 MAINTENANCE Lubrication Guide Always check and change fluids and lubricate greaseable compo nents at the intervals outlined in the Periodic Maintenance Chart beginning on page 63 Items not listed in the chart should be lubri cated at the General Lubrication interval Item Lube Method Engine Oil PS 4 PLUS Performance See page 69 Synthetic 2W 50 Brake Fluid DOT 4 Only See page 82 Transmission Oil AGL PLUS Transmission See page 75 Fluid Front Demand Drive Uni
24. Box Capacity 180 Ibs 81 6 kg Unbraked Trailer Towing Capacity 1786 lbs 810 kg Overall Length 83 in 211 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 50 75 in 128 9 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 65 in 165 cm unloaded Engine EH500PLE Low Torque Capacity 4 Stroke Displacement 498 cc Engine Power 27 kW Bore x Stroke 92x75 Alternator Output 260 w Compression Ratio 10 2 1 Fuel System 40 mm Mikuni carburetor Pilot Jet 40 Main Jet 155 Needle Jet X 6M Jet Needle 6MGHI 194 Pilot Screw By flow taper 12 5 Brass Plug Ignition System Digital CDI Ignition Timing 30 2 5000 RPM Spark Plug Gap NGK BKR6E 035 in 0 9 mm Lubrication System Dry Sump Seat Single Seat length 650 mm Steering System Akerman Principle with handlebar controls Transmission Power System Shaft drive on all wheels Transmission and Gears High Low Neutral Reverse Parking Driving System Type Automatic PVT POLARIS Variable Transmission Based on EU Directive 76 432 EC 120 SPECIFICATIONS SPORTSMAN FOREST 500 Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 9 5 24 cm travel Gear Reduction Low 23 91 1 Gear Reduction Reverse 21 74 1 Gear Reduction For
25. ENANCE Front Gearcase Demand Drive Fluid Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Demand Drive Demand Drive Plus Fluid 265 ml 11 14 N m 15 N m Unit 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 Fluid Level 1 Position the vehicle on a level a surface L 2 Place the transmission in PARK ay 3 Remove the fill plug 4 Add the recommended demand drive fluid as needed 5 Reinstall the fill plug Torque to specification 77 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Change 1 Position the vehicle on a level u surface L 2 Place the transmission in PARK ay 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 on to specification See page 77 7 Add the recommended fluid 8 Reinstall the fill plug Torque to specification 9 Check for leaks E 10 Discard used oil properly 78 MAINTENANCE Carburetor This vehicle is calibrated at the factory for optimal performance at alti tudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet
26. Gl POLARIS The Way Out Sportsman Forest 300 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 xk For your nearest Polaris dealer POLARIS 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 9923430 Rev 01 Printed in USA DARNO DUDE VNDE ULT EL III I HIM WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS owners We proudly produce an excit ing line of utility and recreational products Snowmobiles All terrain vehicles ATVs RANGER utility vehicles e Victory Motorcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Please see your dealer for all of your service needs during and after the warranty period For more information about POLARIS visit us online at www polarisindustries com CY POLARIS The Way Out POLARIS THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS Industries Inc Copyright 2011
27. 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 gaso line No single action on your part will increase the life and performance of your vehicle more than following the procedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with the recommended fuel See page 41 2 Check the oil level Add oil if necessary 3 Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Drive slowly Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 53 6 Pull only light loads 7 Change the oil and filter at 20 hours or one month PVT Break in Clutches Belt Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggres sive acceleration and high speed operation during the break in period If a belt fails always clean away all debris when replacing the belt 52 Pre Ride Checklist OPERATION
28. 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 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 The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions SPORTSMAN FOREST 500 Owner s Manual P N 9923430 2 TABLE OF CONTENTS Introduction x2 cud beoe ERG es 4 sri de C PED 7 Features and Controls 34 Operation 2 252 09 2 ox RE uci ne 51 Winch Guide xpo haere ee eet 56 Emission Control Systems 62 Maintenance c visa he SI RE XXe ra Eq de 63 Specifications 120 POLARIS Products 122 Troubleshooting 123 Warranty i 025 00 806 045 4060 6 05 00 9 oes 127 Maintenance Log ssss 131 Index 2th ct ee eee eye tee ee sees nib 134 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle Yo
29. RIS dealer Solution Replace with lower octane fuel Overuse of choke Inspect clean and or replace spark plugs Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Incorrect jetting See your POLARIS dealer 125 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace if equipped Overuse of choke Inspect clean and or replace spark plugs Water is present in fuel Replace with fresh recommended fuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other me
30. TROUBLESHOOTING Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction Electronic throttle control malfunction See your dealer See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Kinked or plugged fuel vent line Inspect and replace if equipped Incorrect fuel Replace with recommended fuel Incorrect jetting Possible Rich Fuel Cause Fuel is very high octane See your POLA
31. al Switch 36 Turning Around ona Hill 26 27 Turning the Vehicle 19 V Vehicle Identification Numbers 6 Vehicle Immersion 100 101 W Warning Symbols 4 Washing the Vehicle 113 114 Wheel Hub Tightening 90 Wheel Installation 91 Wheel Nut Torque Specifications 90 Wheel Removal 91 Winch Cable Care 57 Winch Operation 60 61 Winch Preparation and Inspection 58 Winch Rigging 59 Winch Safety Precautions 56
32. al for braking if you stall or roll backwards while climbing a hill Never back down a hill 27 SAFETY Driving Safely Driving Through Water Maximum Depth Follow these procedures when driving through water 1 Check water depth and current before crossing 2 Avold 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 Drive slowly Avoid rocks and obstacles 5 Wet brakes may have reduced stopping ability Always test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads 28 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 pro cedure on page 105 A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water A 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
33. al for driving through water Never drive through deep or fast flowing water See page 28 11 SAFETY Operator Safety A Always follow the procedures outlined in this manual for driving in reverse See page 31 A Always use the size and type of tires specified for your vehicle Maintain the proper tire pressure A Never modify this POLARIS vehicle through improper installation or use of accessories A 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 NEVER exceed 80 km h when rear cargo loads are above 34 kg and or front cargo loads are above 17 kg Allowa greater distance for braking 12 SAFETY Operator Safety A 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 A 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 A Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting A Always unlock the steering before starting the engine See page 40 A Hot components can cause serious
34. an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Restrictions This vehicle is approved for OFF ROAD TOWING ONLY Towing a trailer with this vehicle on public roads is prohibited Equipment Modifications The warranty on your POLARIS vehicle may be terminated if any equipment has been added or if any modifications have been made that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers and large racks may change vehicle handling Use only POLARIS approved accessories Know their function and effect on the vehicle 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 Engine Serial Number Fy RS ENIA VIN front or rear frame R Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Operator Safety A WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual A Read and understand all warnings cautions and operating procedures in this manual and on the safety labels bef
35. ar Kilometers gt Engine oil change 1M Perform a break in oil change break in at one month gt General 50 3M 800 Lubricate all fittings pivots lubrication cables etc Shift linkage 50 6M 800 Inspect lubricate adjust E Steering 50 6M 800 Lubricate gt Front suspension 50 6M 800 Lubricate gt Rear suspension 50 6M 800 Lubricate Carburetor float 50 6M 800 Drain bowl periodically and bowl prior to storage E Throttle Cable 50 6M 800 Inspect adjust lubricate E ETC Switch replace if necessary W Choke cable 50 6M 800 Inspect adjust lubricate E replace if necessary E Carburetor air 50 6M 800 Inspect duct for proper seal intake ducts flange ing air leaks Drive belt 50 6M 800 Inspect adjust replace as needed Cooling system 50 6M 800 Inspect coolant strength seasonally pressure test System yearly gt Engine oil change 100 6M 1600 Perform a break in oil change at one month gt Oil filter change 100 6M 1600 Replace with oil change gt Oil tank vent hose 100 6M 1600 Inspect routing condition if equipped r Valve clearance 100 12M 1600 Inspect adjust E Fuel system 100 12M 1600 Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years gt Fuel filter 100 12M 1600 Replace annually a E gt Radiator 100 12M 1600 Inspect clean external surfaces gt Cooling hoses 100 12M 1600 Inspect for leaks gt Engine mounts 100 12M 1600 Inspect Exhaust muffler 10
36. argo loads are above 34 kg and or front cargo loads are above 17 kg TOWING is approved OFF ROAD ONLY Operating this vehicle with a trailer on public roads is prohibited TOWING SPEED should never exceed 16 km h Never exceed 8 km h when towing loads in rough terrain while cornering or while ascending or descend ing hills SAFETY Driving Safely Hauling Cargo Towing Loads Towing is approved OFF ROAD ONLY Operating this vehicle with a trailer on public roads is prohibited Do not exceed the maximum capac ities 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 A Using an improper hitch or exceeding the Maximum maximum tongue weight capacity can 17 cm result in serious damage to the vehicle and will void your warranty Never install a hitch longer than 17 cm Never install automotive accessories on your POLARIS vehicle Always install ci POLARIS approved or equivalent E accessories designed for use on the vehicle 33 FEATURES AND CONTROLS Switches inh All Wheel Drive eh Beam Switch Mode Reverse Override Switch Choke 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
37. arting 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 recom mended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 71 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Clean or replace the breather filter 4 Drain the sediment tube Recoil Housing if equipped 1 Drain the recoil housing See page 106 116 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 stre
38. at excessive speeds which can lead to vehicle overturn SAFETY Operator Safety A 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 A 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 A Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 25 A Always follow the procedures outlined in this manual for crossing the side of a hill See page 24 Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual 10 SAFETY Operator Safety A 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 A Always follow the procedures outlined in this manual for operating over obstacles See page 21 A 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 A Always follow the procedures outlined in this manu
39. brake is engaged could result in an accident and serious injury or death Always release the parking brake lock before operating 39 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unau thorized 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 Reverse the procedure to unlock the steering A The handlebars are locked in the full left position when the steering is locked Always unlock the steering before starting the engine 40 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 ON OFF 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 Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter Fuel Tank Cap This vehicle is equipped with a digital fuel gauge that will indi cate a low fuel condition Refuel when the gauge indicates a low fuel condition Always refuel with the engine stopped and outdoors or in a well venti la
40. burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system For more information about safety contact an authorized POLARIS dealer or visit the POLARIS web site at www polarisindustries com 13 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 pur chase 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 General Alert Multi Lingual Before you operate this vehicle read the owner s manual General Alert A Hill Operation Alert Never operate this vehicle on HILLS steeper than 25 degrees 25 To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually Hill Operation Alert 14 SAFETY Safety Labels and Locations No Passenger Rack Warning Warning Tire Pressure Load Alert Clutch Cover Alert A No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH A Tire Pressure Load Alert TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5
41. cancel the reverse speed limit function The override switch also allows activation of All Wheel Drive in reverse if the AWD switch is on A Activating the override switch with the throttle open and while operating in reverse can cause loss of control Do not activate the override switch while the throttle is open Momentary High Beam Switch Press this switch with your left forefinger to activate the headlight high beam The lights will return to low beam when the switch is released All Wheel Drive Switch See page 44 for all wheel drive information Winch Switch See page 56 for winch information 34 FEATURES AND CONTROLS Switches Main Key Switch q End all electrical power to the vehicle D LIGHTS ON position turns the headlights on G Start the engine The headlights are not on in this position d 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 D orr WE RUN Headlight Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position D High Beam JD Low Beam Headlight Override Signal Switch Switch Horn Switch 35 FEATURES AND CONTROLS Switches Turn Signal Switch QD Push the toggle switch either
42. cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part Reinstall the access panel and secure the front box cover 81 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 ser vice A Operating the vehicle with a spongy brake can result in loss of braking which could cause an accident Never operate the vehicle with spongy feeling brakes If the fluid level is low add DOT 4 brake fluid only See page 122 for the part numbers of POLARIS products A An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A Never store or use a partial bott
43. chanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Debris lodged in screen Solution Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pressure washers can deform the radiator fins and reduce cooling efficiency 126 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 This warranty is transferable to another consumer during the warranty period through a POLARIS dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the
44. clockwise to remove it Clean the filter sealing area on the crankcase Lubricate the filter o ring Check to make sure the o ring is in good condition Install the new oil filter After the filter contacts the crankcase surface turn it 1 2 turn by hand Approximately 240 ml of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to specification MAINTENANCE Engine Oil Oil Change 20 2 22 23 24 25 26 27 28 Remove the dipstick Add 1 9 liters of recommended oil If the sump is not drained add about 1 6 liters initially Reinstall the dipstick Place the transmission in PARK Prime the oil pump using the procedure L on page 74 R Stop the engine Check for oil leaks Check the oil level Add oil as needed A Maintain the oil level in the safe range Do not overfill Safe Range Reinstall the dipstick Add Oil Safe Discard used oil and filter properly 73 MAINTENANCE Engine Oil Oil Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected l 74 Clamp the vent line 5 cm from the oil tank between the end of the oil tank vent fitting and the vent l
45. cluding but not limited to the following items Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps 128 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 The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other f
46. dure 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 101 MAINTENANCE Spark Arrester Occasionally the spark arrester may accumulate carbon which can restrict the exhaust 1f left unattended Purge the spark arrester A 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 Do not stand behind or in front of the vehicle while purging 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the arrester clean out plug from the bottom of the muffler 4 Start the engine 5 Quickly squeeze and release the throttle lever several times to purge car bon from the system 102 MAINTENANCE Spark Arrester 6 10 11 If carbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves Lightly tap on the exhaust pipe with a rubber mallet while repeat ing step 5 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 Place the transmission in PARK Re
47. e breaker Low battery voltage Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Rotates Fails to Start Possible Cause Out of fuel Solution Refuel Clogged fuel valve or filter Replace the filter Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fuel valve is turned off Turn the fuel valve on Fouled or defective spark plug s No spark to spark plug Inspect plugs and replace if necessary Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer 124 Engine Pings or Knocks Possible Cause
48. e 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 61 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compli ance 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 Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design includ ing factory set fuel delivery and ignition The engine and related components must be maintained at POLARIS specifications to achieve optimal performance Engine idle speed is the only adjustment POLARIS recommends that the operator per form Any other adjustments should be performed by an authorized POLARIS dealer Electromagnetic Interference This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or control ling devices should review the limitations of their device and the applicable electro magnetic standards and directives that apply to this vehicle European Vibration and No
49. e wheels are installed properly Replace tires when the tread depth measures 3 mm or less Refer to the specifications section beginning on page 120 for recom mended tire type size and pressure Tire Tread Depth i Always replace tires 3mm when tread depth is worn to 3 mm or less XS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized POLARIS dealer Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Type Nut Torque Lug Nut Aluminum Wheels 41 N m PLUS 1 4 TURN rices plande Nut 37 N m eel Wheels ty 90 MAINTENANCE Tires Wheel Removal Installation A 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 Place the wheel on the hub 8 Install the wheel nuts finger tight 9 Lower the vehicle to the ground 10 Torque the wheel nuts to specification See torque chart on page 90 91 MAINTENANCE Air Filter Always clean and replace the air and breather filters a
50. eded Maintain the oil level in the safe range Do not overfill Safe Range 8 Reinstall the dipstick 70 MAINTENANCE Engine Oil Oil Change A 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 Drain under the oil tank Plug 7 Remove the drain plug 8 Drain the oil Q ae IU y WP Screen M Fitting New Sealing Washer 9 Clean the drain plug Reinstall the drain plug with a new sealing washer O 10 Torque to specification See page 69 71 MAINTENANCE Engine Oil Oil Change 11 12 Tip 13 14 15 16 17 18 Tip 19 72 Disconnect the lower oil deliv ery 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 Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1 2 turns into the tank threads Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank Do not over tighten Maximum torque for the screen fitting is 34 N m Reattach the oil line Place towels under the oil filter Using an oil filter wrench turn the filter counter
51. ehicle If you discover improper alignment see your POLARIS dealer for service 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 A 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 Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Tip Be sure the handlebars do not con tact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 14 17 N m then torque the rear two bolts A gap of up to 3 mm will remain at the rear bolts Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension 87 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
52. esso ries Accessory outlets are available for all models POLARIS also has a wide range of additional accessories available for your vehicle Always install accessories that are approved for use on this vehicle Please see your POLARIS dealer 118 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle l 2 3 Stop the engine ao H Place the transmission in PARK a 4 N Secure the fuel cap oil cap and y seat Remove the key to prevent loss during transporting 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 Towing a Disabled Vehicle If towing the vehicle 1s necessary shift the transmission into neutral for better mobility and to prevent damage to the belt Always attach the tow rope to the frame of the POLARIS vehicle 119 SPECIFICATIONS SPORTSMAN FOREST 500 Maximum Weight Load Capacity 485 Ibs 220 kg operator cargo accessories Dry Weight 325 kg 7 based on configuration Fuel Capacity 4 25 gal 16 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 2 7 qts 2 5 1 Demand Drive Fluid Capacity 9 oz 265 ml Transmission Oil Capacity 32 oz 948 ml Front Rack Storage Box Capacity 90 Ibs 41 kg Rear Rack Storage
53. etor Adjustment 79 CArBO s Deo py eris Ue es 32 33 Choke i liilzelie exu ees 41 Chrome Wheel Care 115 Cleaning and Storage 113 118 Clothing iy in eh RS epe 17 Clutching 04 121 Cold Weather Operation 55 Coolant Bottle 80 Coolant Radiator 81 Cooling System 80 81 Corrosion Removal Chrome 115 134 D Demand Drive Fluid 77 78 Drive Belt Wear Burn 123 Drivetrain Break In 52 Driving Downhill 25 Driving in Reverse 31 Driving on a Sidehill 24 Driving on Slippery Surfaces 20 Driving Over Obstacles 21 Driving Procedures 18 Driving Safely 18 33 Driving Through Water 28 29 Driving Uphill 22 23 E Electromagnetic Interference 62 Electronic Throttle Control 37 Engine Break In 52 Engine Fogging 117 Engine Idle RPM Adjustment 79 Engine Oil 69 74 Equipment Modifications 5 Exhaust Emission Control System 62 Eye Protection 17 F Fluid Brake 008 0 eene bts 82 84 Demand Drive 77 78 Engine Oil 69 74 Transmission 75 76 Fluid Change Demand Drive 78 Engine Oil 72 Transmission 76 Fluid Level Demand Drive
54. h PVT Drying There may be some instances when water is accidently ingested into the PVT system Dry it out before operating 1 2 Position the vehicle on a level surface Place the transmission in PARK Remove the drain plug Allow the water to drain completely Reinstall the drain plug Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 105 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 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 com pletely 5 Reinstall the drain screw Tip Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crankcase drain is opened 106 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting batte
55. harger use the following guidelines for recharging A An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Always verify battery condition before and 1 2 hours after the end of charging Faol Voltage Action E Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 112 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear ance 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 Usea professional type washing cloth cleaning the upper body first and the lower parts last 2 Ri
56. he setting by one hour Press and hold the mode button to advance the hours quickly If you scroll past the intended number press and hold the button until the hours cycle back to zero When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement l 2 50 Enter the diagnostic mode Toggle to the screen that displays either kilometers KM or miles MP Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set OPERATION Fuel Safety 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 refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Turn the fuel valve off whenever the vehicle is stored or parked 51 OPERATION Break
57. ine s pressure relief slit Start the engine Allow it to idle for 10 20 seconds Remove the vent line clamp If Tank 5 cm lt gt Clamp Pressure Relief Slit the line is bled properly you should hear a rush of air If you do not hear a rush of air repeat the priming procedure 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 Fill Plug Drain Plug Capacity Torque 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 Maintain the level at the bottom of the fill hole threads 5 Addtherecommended oil as needed Do not overfill 6 Reinstall the fill plug Torque to specification Fill Level 75 MAINTENANCE Transmission Oil Oil Change 1 Position the vehicle on a level surface 2 Place the transmission in PARK Remove the fill plug Remove the drain plug Drain the oil into a drain pan Clean the drain plug poy GU e os Reinstall the drain plug Torque to specification See page 75 Add the recommended oil 9 Reinstall the fill plug Torque to specification Drain Plug 10 Check for leaks 11 Discard used oil properly 76 MAINT
58. ise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature 62 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 If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Sho
59. k ing 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 grav ity to 1 270 or greater 3 Reinstall the battery See page 109 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery 1s sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage 111 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 Ifthe 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 manufac turer s instructions for recharging When using a constant current c
60. le of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 82 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 win dow eye on the top of the master cylinder Tip The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed Do not overfill 83 MAINTENANCE Brake Fluid Foot Brake 1 Position the vehicle on a level surface 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 84 Foot Brake Fluid Reservoir MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by apply ing 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 s
61. manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE KILOMETERS TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 131 MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 132 MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 133 INDEX A Accessories llle 118 Age Restrictions 5 Air Filter 00 00 00 0000 ee 92 All Wheel Drive Switch 34 All Wheel Drive System 44 AWD System 004 44 B Battery eese 107 112 Charging Conventional 111 Charging Sealed 111 112 Fluid Conventional 110 Installation 109 Removal csie sassari eraai 108 Storage n u ununuran 110 Belt Tite ins oem ets 42 Boots reete ose OE ones 17 Brake Flud eo ores 82 84 Brake Inspections 85 Brake Foot 0 0005 38 Brake Hand 00 38 Brake Parking 39 Brak OS 2 2 o sob eX 85 Break In Period Lus 52 Breather Filter 93 Breather Hose 93 C Carburetor 0 00005 79 Carbur
62. n this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 23 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 Slow down Avoid hills with excessively slippery or loose surfaces Shift your weight uphill Avoid crossing the sides of steep hills Keep your feet on the footrests Steer slightly into the hill If the vehicle begins to tip quickly turn the front wheels downhill if possible or dismount on the uphill side immediately A Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual SO qe US B o 24 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 A Always follow the procedures outlined in this manual for driving downhill and for braking on hills A
63. ng 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 Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Rid ing pants with kneepads and a jersey with shoulder pads provide the best protection 17 SAFETY Driving Safely Driving Procedures IASON Cp Beet 18 Sit upright Keep your feet on the footrests Keep both hands on the handlebars Apply the brakes Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the brakes Slowly squeeze the throttle lever toward the handlebar to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Driving Safely Turning the Vehicle l Always follow the procedures outlined in this manual for turning Never turn sharply at excessive speeds which can lead to vehicle Before turning activate a turn signal to alert others of your inten tions Activate the left signal before a left turn Activate the right signal before a right turn S
64. ngth fill Fog the Engine l 2 3 Treat the fuel system with POLARIS Carbon Clean See page 116 Remove the spark plug Pour 30 45 ml of engine oil into the plug holes Reinstall the spark plugs Torque to specification Apply dielectric grease to the inside of each spark plug cap Rein stall the caps Turn the engine over several times using the recoil starter if equipped Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil If POLARIS fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops 117 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 Be sure the storage area is well ventilated 3 Cover the vehicle with a genuine POLARIS cover Do not use plas tic or coated materials They do not allow enough ventilation to pre vent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating acc
65. nse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 113 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 Avoid directing the water stream at the follow ing items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Electrical components Switches and controls Labels and decals If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Polishing Tips Avoid the use of autom
66. ore operating the vehicle Never operate this vehicle without proper instruction Take a training course Beginners should receive training from a certified instructor Never permit others to operate the vehicle unless they have read and understand this manual and all product labels and have completed a certified safety training course A Never allow anyone under 16 years of age to operate this vehicle A Never carry a passenger The purpose of the long seat is to allow the operator to shift position SAFETY Operator Safety A Always wear an approved helmet that fits properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants A Never consume alcohol or drugs before or while operating this vehicle A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience A Never attempt jumps or other stunts SAFETY Operator Safety A 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 A Keep both hands on the handlebars Keep your feet on the footrests A Always travel slowly when operating on unfamiliar terrain Use extra caution A Always follow the procedures outlined in this manual for turning See page 19 Never turn sharply
67. oreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 129 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 materi als or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR POSE Some states do not permit the exclusion or limitation of incidental or consequen tial damages or implied warranties so the above limi
68. original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR POLARIS VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 127 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 This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond POLARIS control Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended in
69. otive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 114 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 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 Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 115 MAINTENANCE Cleaning and Storage Storage Tips A St
70. ow ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Climbing over large objects from a stopped position Shift the transmission to low range Carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Dry out the PVT See page 105 Inspect clutch seals for damage if repeated leaking occurs See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 48 km h for 1 6 km Operate 8 km or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 52 123 TROUBLESHOOTING Engine Does Not Rotate Possible Cause Tripped circuit breaker Solution Reset th
71. peat steps 5 to 7 until 30 cm no more particles are expelled Stop the engine Allow the arrester to cool Reinstall the arrester plug and remove the exhaust outlet cover or plug 103 MAINTENANCE PVT System A 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 However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 104 MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 11 km h Hig
72. ration NOTICE This winch is designed for intermittent use Prolonged use may result Uh e DE k 7 8 9 10 11 12 60 in damage due to overheating 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 Extended winching will discharge your battery If the low battery warning light comes on stop winching Make sure the transmission is in neutral or park then rev the motor for a few minutes until the warning light goes out Recharge the battery as soon as possible DO NOT overload or stall the winch If the load 1s greater than the winch is capable of pulling use a snatch block Avoid continuous side pulls Never tow the vehicle by the winch cable Never use the winch cable as a tie down Use an anchor point that is stronger than what you are pulling DO NOT hook the cable back onto itself This will damage the cable 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 th
73. re Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride Winch Pre Ride See pages 57 58 gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years Headlight taillight Daily Check operation apply dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element Recoil housing Weekly Drain water as needed if equipped check often if operating in wet conditions gt Brake pad wear 10 Monthly 160 Inspect periodically L Battery 20 Monthly 300 Check terminals clean test gt Demand drive fluid 25 Monthly 400 Inspect level change yearly front gearcase gt Rear gearcase oil 25 Monthly 400 Inspect level change yearly if equipped gt Transmission oil 25 Monthly 400 Inspect level change yearly gt Engine breather 25 Monthly 400 Inspect clean if needed E filter if equipped gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service W Have an authorized POLARIS dealer perform these services 65 MAINTENANCE Periodic Maintenance Chart 66 Item Maintenance Interval Remarks whichever comes first Hours Calend
74. recommends the use of POLARIS Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Premium 60 40 is pre mixed and ready to use Do not dilute with water See page 122 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant Some coolant level drop on new machines is normal as the system is purging itself of trapped air Add coolant as needed Tip Check the coolant level in the radi ator any time the recovery bottle has run dry 1 Check the coolant level when the fluid is cool Maintain the coolant level between the mini mum and maximum marks on the bottle when the fluid is cool 2 Remove the left side panel See page 88 Recovery Bottle 3 View the coolant level Add coolant as needed 5 Reinstall the side panel 80 MAINTENANCE Cooling System Radiator Coolant A Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot l 2 Open the front box cover Remove the access panel 4 V screws Squeeze the outer edges of the panel inward to remove the panel E Remove the radiator pressure cap If coolant is not visible slowly add coolant through the radiator filler neck Radiator Reinstall the pressure cap Use of a non standard pres sure
75. rt trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 63 MAINTENANCE Periodic Maintenance Chart A 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 P 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 E Have an authorized POLARIS dealer perform these services 64 Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Kilometers Steering Pre Ride Make adjustments as need n n ed See Pre Ride Checklist Front suspension Pre Ride on page 53 Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake lever Pre Ride Foot brake P
76. ry 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 A 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 Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution
77. s and turn the locking collar counter clockwise left headlight or clockwise right headlight to release the lamp assembly 5 Install the new lamp Apply a Socket am small amount of dielectric grease B to the lamp socket or terminals E uo 6 Reverse all steps to reassemble P components T 95 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 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 Ifa front turn signal light becomes inoperable the lamps cannot be replaced Replace the entire signal lamp assembly Rear Turn Signal Lamp Replacement 1 Place the transmission in PARK 2 Rotate the turn signal socket counter clockwise to remove it 3 Remove the lamp Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for proper operation 6 Reinstall all components in reverse order 96 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
78. spect 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 A DANGER Never touch the cable or hook while they are in tension or under load Even at rest the winch may have the cable in tension Never guide a cable under tension onto the drum with your hand 1 Winch with at least five wraps of cable around the winch drum With fewer wraps the cable could pull loose from the drum under load 58 WINCH GUIDE Winch Rigging A 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 Usea nylon sling to attach the cable to an anchor point CAUTION Donotattach the hook back onto the cable Doing so can cause the cable to break A WARNING Always use a handsaver Do not hold the hook with your hand This is important not only when reeling cable in but also when removing cable from the winch under power 2 Runthe winch intermittently to take up cable slack When using a pulley p block be sure the cable is running S properly in all pulleys before apply Cc ing a load CAUTION Never engage or disengage the clutch if the winch is under load the cable is in tension or the drum is rotating 59 WINCH GUIDE Winch Ope
79. stments 98 Spark Plugs Spark Plug Removal 1 Remove the left side panel See page 88 2 Remove the spark plug cap 3 Usethe spark plug wrench to remove the spark plug Turn the plug counter clockwise 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 99 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 pro cedure A 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 4 Remove the spark plug 5 Loosen the carburetor drain screw and drain the carburetor 6 Turn the engine over several times using the electric start Drain Screw 100 MAINTENANCE Vehicle Immersion 7 10 Attempt to start the engine If 11 Have the vehicle serviced by Dry the spark plug Reinstall the plug or install a new plug Torque to specification See page 98 Tighten the carburetor drain screw Turn the fuel valve on necessary repeat the drying proce
80. t Front Gearcase Demand Drive Plus Fluid See page 77 Front Prop Shaft Yoke POLARIS Premium U Joint Grease fittings 3 pumps maxi Lube mum every 800 km before long periods of storage or after pres sure washing or submerging 68 Front Prop Shaft Yoke 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 1f 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 A Mixing brands or using a non recommended oil may cause serious engine damage Always use a recommended oil Never substitute or mix oil brands Oil Specifications Model Lubricant Capacity Drain Plug Torque SPORTSMAN PS 4 PLUS Performance 1 9 liters 19 23 N m Forest 500 Synthetic 2W 50 4 Cycle Oil 69 MAINTENANCE Engine Oil Cil 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 Dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely ESNA 7 Remove the dipstick and check the oil level Add oil as ne
81. t intermittent use of the choke pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 11 If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in Cold Weather Operation Internal engine condensation increases as outside temperatures decrease If the vehicle is used year round check the oil level fre quently A rising oil level could indicate the accumulation of contami nates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases See your POLARIS dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 55 WINCH GUIDE The responsibility for safe operation of the winch ultimately rests with you the operator Read and understand all safety precautions and oper ating 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
82. t the intervals out lined 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 Release the air box cover clips 5 Remove the air box cover 6 Loosen the hose Pre Filter clamp Remove the filter i Main Filter 8 Remove the pre filter L from the filter S 5 9 Wash the pre filter in soapy water Rinse and air dry 10 Replace the filter if needed 11 Reverse the steps to reinstall all components 92 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 Breather damaged or clogged filter Filter 4 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter and hose clamps Tip The filter is effective with the arrow pointing in either direction A Operation of your vehicle without a breather filter can cause engine damage 93 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
83. tarter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 43 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 Ifthe 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 If the rear wheels are spinning release the throttle before switching to AWD Tip The override switch allows activation of AWD in reverse if the AWD switch is on See page 34 A Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest AWD When the AWD switch is on the vehicle is in four wheel ir T drive and the differential is E NR locked providing maximum LH traction The demand drive T ar unit automatically engages when the rear wheels lose trac tion When the rear wheels
84. tations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS dealer autho rized to repair POLARIS vehicles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANS PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 130 MAINTENANCE LOG Present this section of your
85. ted area Refuel on a level surface Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 per cent such as E 85 fuel 41 FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is located on the right side of the Selector vehicle High Gear Low Gear Neutral Reverse Park To shift gears brake to a com plete stop When the engine is idling move the lever to the desired gear Sm Lu 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 The transmission is locked when it s in PARK Belt Life To extend belt life use low forward gear when pulling a heavy load at less than 11 km h for extended periods and when operating uphill at a slow speed 42 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 starter instead of the main key switch 1 Grasp the recoil starter rope handle tightly SA d 2 Pull slightly until the starter Recoil Starter JAV mechanism engages 3 Pull the rope abruptly to start the engine A Extending the recoil s
86. teer 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 SAFETY 7 RY zh LS KLA Sg AVE Practice turning at slow speeds before attempting to turn at faster speeds overturn A 19 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 handle bars in the same direc tion as the skid and shift body weight forward NOTICE Severe damage Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid to the drive train may occur if AWD is engaged while the wheels are spinning Engage Sideways Turn in direction skid of skid re PISS t oe O Cac ed s e AWD when the wheels have traction skidding or sliding 20 A 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
87. the red positive cable first Connect and tighten the black negative cable last Secure the battery hold down strap Reinstall the battery cover 1f equipped Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 10 Reinstall the seat 109 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 self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 122 for the part numbers of POLARIS products Battery Fluid Conventional Battery Check the battery fluid level Lower Upper often Maintain the fluid level Mark Mark between the upper and lower level marks Add only distilled water Tap o water contains minerals that are harmful to a battery Gb PLAAS 110 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from lea
88. ur safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A 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 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 INTRODUCTION 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 For more information about safety contact an authorized POLARIS dealer or visit the POLARIS web site at www polarisindustries com Age Restrictions This vehicle is
89. ver 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 Avoid situations that require backing downhill When operating over rough or hilly terrain reduce speed cargo and towed load to maintain stable driving conditions CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition Reduce load weight when cargo is high Secure off centered loads that cannot be centered and operate with extra caution CARRYING A LOAD on only one rack may cause the vehicle to overturn Split the load between the front rack and rear rack with 1 3 in the front and 2 3 in the back Do not exceed load capacities See specifications beginning on page 120 SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehi cle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn NEVER exceed 80 km h when rear c
90. voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedome ter If this occurs take the vehicle to your POLARIS dealer for proper diagnosis l Qu nt 46 Gear Indicator This 3 4 5 indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park AWD Indicator This indicator illuminates when the AWD switch is in the AWD position Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator Odometer Tachometer Tripmeter Hour Meter Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately Check Engine Warning Indicator The word HOT displays if the engine overheats Do not operate the vehicle if this warning appears Serious engine damage could result Mode Indicator 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
91. ward 10 57 1 Drive Ratio Front 3 82 1 Tires Type Front Off Road Style Deep Tread Design Size 25x8 12 5 psi 34 5 KPa Tires Type Rear Off Road Style Deep Tread Design Size 25x11 12 5 psi 34 5 KPa Brakes Front Rear Single Control handlebar hydraulic disc on all wheels Brakes Auxiliary Foot Activated Hydraulic Disc on all wheels Parking Brake Hydraulic lock on all wheels Mechanical Lock in Park Hitch Rear mount for attachment of coupling devices Winch Front permanent Installed winch with 2500 Lbs 1 125 Kg Capacity Headlight 2 dual beam on bumper 55 60 watt Parking Lights 5 watts Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Jetting Chart ALTITUDE Bas sid Hisce Meters Feet elow 40 F and above Below 5 C 5 C and above 0 1800 0 6000 160 155 1800 3700 152 5 147 5 6000 12000 Clutching Altitude Shift Drive Clutch Driven Clutch Helix Spring Weight Spring Spring Setting Meters 0 1800 10 WHF Blue Green Black 41 37 Feet 0 6000 PN 5632283 PN 7041157 PN 7041782 PN 5132344 2 2 1800 3700 10 RH Blue Green Black 41 37 6000 12000 PN 5630709 PN 7041157 PN 7041782 PN 5132344 2 2 121 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol
92. ystems in good operat ing 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 Check the brakes for excessive travel or spongy feel 4 Checkthe friction pads for wear damage and looseness Replace the pads when the friction material is worn to 1 mm 5 Check the security and surface condition of the disc 85 MAINTENANCE Toe Alignment A 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 l 2 86 Position the vehicle on a level surface Place the handlebars in a straight ahead position Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should A Stand String 2 9 1 O FRONT be 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 3 6 mm toe out alignment Repeat the measurement procedure on the other side of the v

2012 FOREST 500.fm

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