Polaris Sportsman 500 EFI X2 Bedienungsanleitung

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of uti

10SAFETYSafety Decals and LocationsRack Warning, FrontWARNINGDO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injur

100MAINTENANCEFront Gearcase (Demand Drive) FluidFluid Level1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level

101MAINTENANCEActive Descent Control (ADC) FluidFluid Level1. Open the front box cover and pull open the access door.2. View the fluid level in the re

102MAINTENANCECooling SystemThe engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the reco

103MAINTENANCECooling SystemRadiator CoolantTo ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain

104MAINTENANCEBrakesHand BrakeThe front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. Th

105MAINTENANCEToe AlignmentUse the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4&qu

106MAINTENANCESteering AssemblyThe steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are f

107MAINTENANCETiresRefer to the specifications section beginning on page 144 for recom-mended tire type, size and pressure.Tire Tread DepthAlways repl

108MAINTENANCETiresWheel Installation1. Place the transmission in PARK.2. Lock the parking brake.3. Place the wheel on the hub with the valve stem tow

109MAINTENANCEAir Filter1. Remove the seat.2. Release the air box cover clips, and remove the air box cover.3. Loosen the clamp and remove the filter.

11SAFETYSafety Decals and LocationsReverse Override WarningWARNINGPushing reverse override button may cause sudden increases in power and traction if

110MAINTENANCEBreather Filter/Hose (500 EFI)The breather filter is on the hose that runs between the engine and air box.1. Remove the left side panel.

111MAINTENANCEFuse ReplacementIf the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace-ment.NOTE

112MAINTENANCELightsWhen servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spo

113MAINTENANCELightsHigh Beam AdjustmentThe headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjust

114MAINTENANCELightsHeadlight Housing Replacement1. Remove the two screws on the lower front corners of the headlight pod.2. Lift the pod slightly whi

115MAINTENANCELightsLower Headlamp Replacement1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the h

116MAINTENANCESpark PlugsSpark Plug RecommendationsRefer to the specifications section beginning on page 144 for the recom-mended spark plug type and

117MAINTENANCESpark PlugsSpark Plug InspectionNormal Spark PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion depo

118MAINTENANCEVehicle Immersion1. If it's impossible to take your ATV to a dealer before starting it, fol-low the steps outlined below.2. Move th

119MAINTENANCESpark ArrestorUse the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler.1. Remove the arrestor

12SAFETYSafe Riding GearAlways wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.H

120MAINTENANCEPVT SystemWARNINGFailure to comply with the instructions in this warning can result in severe injury or death.Do not modify any componen

121MAINTENANCEPVT SystemThe basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed in

122MAINTENANCEPVT SystemWhen To Use Low Range and High RangePVT DryingThere may be some instances when water is accidently ingested into the PVT syste

123MAINTENANCEBatteryYour ATV may have either a sealed battery, which requires little mainte-nance, or a conventional battery. A sealed battery can be

124MAINTENANCEBatteryBattery Removal1. Loosen the battery hold-down bolt.2. Remove the battery cover.3. On conventional batteries, remove the battery

125MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It

126MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure

127MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electrol

128MAINTENANCEBatteryBattery Charging (Sealed Battery)NOTE: Always verify battery condition before and 1-2 hours after the end of charging.State of Ch

129MAINTENANCECleaning and StorageWashing the VehicleKeeping your Polaris vehicle clean will not only improve its appearance but it can also extend th

13SAFETYSafe Riding GearEye ProtectionDo not depend on eyeglasses or sunglasses for eye protection. When-ever riding a Polaris vehicle, always wear sh

130MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

131MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life an

132MAINTENANCECleaning and StorageStorage TipsClean the ExteriorMake any necessary repairs and clean the vehicle as recommended. See page 129.Stabiliz

133MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Ch

134MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Per

135MAINTENANCETransporting the ATVFollow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in PARK.3. Lock t

136ADJUSTMENTSCamber and CasterThe camber and caster are non-adjust-able.Rear SpringThe rear shock absorber spring is adjusted by rotating the adjuste

137ADJUSTMENTSHandlebarsThe handlebars can be adjusted for rider preference.1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts.3. A

138ADJUSTMENTSThrottle Body/Idle RPMIdle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris deal

139TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionDriving onto a pickup or tall trailer in high rangeUse low range during loading.Starting

14SAFETYRider SafetyAge RestrictionsThis vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Never allow anyon

140TROUBLESHOOTINGEngine Doesn't Turn OverEngine Turns Over, Fails to StartEngine BackfiresPossible Cause SolutionLow battery voltage Recharge th

141TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

142TROUBLESHOOTINGEngine Stops or Loses PowerEngine OverheatingPossible Cause SolutionOut of fuel Refuel, cycle key to ON position three times for 5 s

143POLARIS PRODUCTSPart NumberDescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil

144SPECIFICATIONS* Based on EU Directive 76/432/ECSportsman X2 500 EFIMaximum Weight Capacity 705 lbs. (320 kg) (includes operator, passen-ger, cargo

145SPECIFICATIONSClutching (EBS Models)NOTE: *EBS models require no helix/spring adjustmentSportsman X2 500 EFITransmission Automatic EBS (Engine Brak

146SPECIFICATIONSSportsman X2 700 EFIMaximum Weight Capacity 705 lbs. (320 kg) (includes operator, passenger, cargo, accessories)Dry Weight 830 lbs. (

147SPECIFICATIONSClutching (EBS Models)NOTE: *EBS models require no helix/spring adjustmentSportsman X2 700 EFITransmission Automatic EBS (Engine Brak

148SPECIFICATIONS* Based on EU Directive 76/432/ECSportsman X2 800 EFIMaximum Weight Capacity 705 lbs. (320 kg) (includes operator, passen-ger, cargo,

149SPECIFICATIONSClutching (EBS Models)NOTE: *EBS models require no helix/spring adjustmentSportsman X2 800 EFITransmission Automatic EBS (Engine Brak

15SAFETYRider SafetySafety TrainingATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on t

150WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris

151WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

152WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE) ARE L

153WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

154WARRANTYExported VehiclesHow to Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen outside of th

155WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in add

156MAINTENANCE LOGPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

157MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

16SAFETYRider SafetyThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words

17SAFETYRider Safety• Read this manual and all labels carefully, and follow the operating procedures described.• Never operate an ATV without proper i

18SAFETYRider Safety• Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield),

19SAFETYRider Safety• Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2007 Polaris Sales Inc. All information contained with

20SAFETYRider Safety• Always check for obstacles or people behind the ATV before operat-ing in reverse. Be aware that a passenger can obstruct your vi

21SAFETYRider SafetyEquipment ModificationsWe are concerned for the safety of our customers and for the general public. Therefore, we strongly recomme

22SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly increased i

23SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating with more than one passenger.WHAT CAN HAPPENPassengers affect balance and steering and increase t

24SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another v

25SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption of alcohol and/or drugs could

26SAFETYRider SafetyWARNINGPOTENTIAL HAZARDAttempting jumps and other stunts.WHAT CAN HAPPENAttempting stunts increases the chance of an accident, inc

27SAFETYRider SafetyWARNINGPOTENTIAL HAZARDRemoving hands from the handlebars or feet from the footrests during operation.WHAT CAN HAPPENRemoving even

28SAFETYRider SafetyWARNINGPOTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPEN

29SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating on excessively steep hills.WHAT CAN HAPPENThe vehicle may overturn.HOW TO AVOID THE HAZARDNever o

3TABLE OF CONTENTSKnow Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30SAFETYRider SafetyWARNINGPOTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or ov

31SAFETYRider SafetyWARNINGPOTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning on hills could

32SAFETYRider SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle coul

33SAFETYRider SafetyWARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or

34SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CAN HAPPENTires may float, causing loss of tracti

35SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating this ATV with improper tires, or with improper or uneven tire pressure.WHAT CAN HAPPENUse of impr

36SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause cha

37SAFETYRider SafetyWARNINGOperating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qual

38FEATURES AND CONTROLSSwitchesMode/Reverse Override SwitchThis vehicle is equipped with a reverse speed limiter system.To gain additional power while

39FEATURES AND CONTROLSSwitchesDifferential SwitchUse the differential switch to lock and unlock the rear differential.Locked Differential: Operate th

4

40FEATURES AND CONTROLSThrottle LeverEngine speed and vehicle move-ment are controlled by pressing the throttle lever. The throttle lever is spring lo

41FEATURES AND CONTROLSBrake LeverSqueeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically acti

42FEATURES AND CONTROLSMaster Cylinder/Brake FluidCheck the brake fluid in the master cylinder before each ride. The fluid level can be seen through a

43FEATURES AND CONTROLSParking BrakeLocking the Parking Brake1. Place the transmission in PARK.2. Squeeze and release the brake lever two or three tim

44FEATURES AND CONTROLSAuxiliary Foot BrakeThe auxiliary brake system is intended to be used as a backup for the main brake system. Should the main sy

45FEATURES AND CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector is located on the right side of the vehicle. H: High GearL:

46FEATURES AND CONTROLSRecoil Starter (500 EFI)If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures

47FEATURES AND CONTROLSAll Wheel Drive SystemThe All Wheel Drive system is controlled by the 4X4 switch.ADC 4X4 ModeWhen the switch is on ADC 4X4, the

48FEATURES AND CONTROLSAll Wheel Drive System Engaging 4X4The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle&a

49FEATURES AND CONTROLSActive Descent Control (ADC) SystemThe ADC system allows engine braking to all four wheels when the vehicle descends a hill or

5KNOW YOUR VEHICLEAs the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and t

50FEATURES AND CONTROLSPassenger SeatAlways make sure the passenger seat lock-out is functioning properly before operating with a passenger.Do not ope

51FEATURES AND CONTROLSPassenger SeatSeat Conversion5. Lift the adjustment latch at the top of the passenger backrest. Raise the backrest to the desir

52FEATURES AND CONTROLSInstrument ClusterYour ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission.

53FEATURES AND CONTROLSInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. All seg-ments will

54FEATURES AND CONTROLSInstrument ClusterRider Information CenterStandard ModesUse the MODE button to toggle through the mode options. The reverse ove

55FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeThe wrench icon will display when the gauge is in the diagnostic mode.

56FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeBattery Voltage ScreenView this screen to check battery voltage level.

57FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeProgrammable service intervalTo enable or disable the service interval

58FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesThe EFI diagnostic mode is for informational purposes only. Please s

59FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesBlink CodeFailure Description12 BEGIN SEQUENCE22 Throttle Position S

6SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on th

60OPERATIONFuel SafetyWARNINGGasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling g

61OPERATIONBreak-In PeriodThe break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two

62OPERATIONPre-Ride ChecklistWARNINGIf a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicl

63OPERATIONStarting the Engine1. Position the vehicle on a level surface.2. Place the transmission in PARK.3. Lock the parking brake.NOTE: The starter

64OPERATIONHauling CargoWARNINGOverloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control

65OPERATIONHauling CargoYour ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warn-ing

66OPERATIONHauling CargoTowing LoadsAlways attach a towed load to the hitch point. If towing a load, reduce rear box cargo weight by the amount of ton

67OPERATIONHauling CargoDumping Cargo1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an inc

68OPERATIONDriving Procedures1. Wear protective riding gear. See page 12.2. Perform the pre-ride inspection. See page 62.3. Place the transmission in

69OPERATIONTurning the VehicleBoth rear wheels drive equally at all times (except when operating in 2X4 mode with the differential unlocked). This mea

7SAFETYSafety Decals and LocationsGeneral WarningWARNINGImproper ATV use can result in SEVERE INJURY or DEATHALWAYS USE AN APPROVED HELMET AND PROTECT

70OPERATIONDriving with a Passenger1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and gr

71OPERATIONDriving with a Passenger10. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers

72OPERATIONDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel, or during freez-ing weather, follow th

73OPERATIONDriving UphillWhenever traveling uphill, follow these precautions:1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a

74OPERATIONDriving on a Sidehill (Sidehilling)Sidehilling can be dangerous and should be avoided if at all possible. If you encounter a situation wher

75OPERATIONDriving DownhillWhen driving downhill, follow these precautions:1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a h

76OPERATIONTurning 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.8

77OPERATIONTurning Around on a Hill (K-Turn)1. Stop and lock the parking brake while keeping body weight uphill.2. Always move the 4X4 switch to ADC 4

78OPERATIONDriving Through WaterYour ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these

79OPERATIONDriving Through WaterAfter running the vehicle in water, it's critical to have it serviced as out-lined in the maintenance chart. See

8SAFETYSafety Decals and LocationsPassenger Safety WarningWARNINGPASSENGER SAFETYTo reduce the risk of SEVERE INJURY or DEATHNEVER CARRY A PASSENGER U

80OPERATIONDriving Over Obstacles1. Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such

81OPERATIONParking on an InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Plac

82OPERATIONDriving in ReverseWARNINGFailure to use caution when operating in reverse can result in serious injury or death. Before shifting into rever

83OPERATIONDriving in ReverseFollow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle. Be aware t

84EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

85MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, ad

86MAINTENANCEPeriodic Maintenance ChartMaintenance Chart KeyX Perform these operations more often for vehicles subjected to severe use.E Emission-rel

87MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)XEAir filter,main element- Weekl

88MAINTENANCEPeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related ServiceQ Have an

89MAINTENANCELubrication GuideCheck and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Ite

9SAFETYSafety Decals and LocationsTire Pressure/Load WarningWARNINGIMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE

90MAINTENANCEEngine OilOil RecommendationsPolaris recommends the use of Polaris PS-4 PLUS Performance Syn-thetic 2W-50 4-cycle oil or a similar oil fo

91MAINTENANCEEngine OilOil Level (500 EFI)Access the oil dipstick and fill tube from the left side of the ATV.NOTE: A rising oil level between checks

92MAINTENANCEEngine OilOil Level (700/800 EFI)Access the oil dipstick and fill tube from the left side of the ATV.1. Position the vehicle on a level s

93MAINTENANCEEngine OilOil and Filter Change (500 EFI)Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beg

94MAINTENANCEEngine OilOil and Filter Change (500 EFI)12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counte

95MAINTENANCEEngine OilOil and Filter Change (500 EFI)Oil Pump PrimingThis priming procedure must be performed whenever the oil hose connection betwee

96MAINTENANCEEngine OilOil and Filter Change (700/800 EFI)Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart

97MAINTENANCEEngine OilOil and Filter Change (700/800 EFI9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your

98MAINTENANCETransmission OilAlways check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on pag

99MAINTENANCETransmission OilTransmission Oil Change1. Remove the fill plug.2. Place a drain pan under the gearcase.3. Remove the drain plug. Allow th