Polaris 2011 ATV Sportsman Forest 500 Bedienungsanleitung

Owner's Manualfor Maintenance and SafetyRead this manual carefully. It contains important safety information.This is an adult vehicle only.Operat

8SAFETYOperator SafetyAlways wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and

98MAINTENANCESpark PlugsSpark Plug RecommendationsRefer to the specifications section beginning on page 120 for the recom-mended spark plug type and g

99MAINTENANCESpark PlugsSpark Plug Removal1. Remove the left side panel. See page 88.2. Remove the spark plug cap.3. Use the spark plug wrench to remo

100MAINTENANCEVehicle ImmersionIf your vehicle has been totally submerged in water and it's impossible to have it serviced before further operati

101MAINTENANCEVehicle Immersion7. Dry the spark plug. Reinstall the plug or install a new plug. Torque to specification. See page 98.8. Tighten the ca

102MAINTENANCESpark ArrestorOccasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark

103MAINTENANCESpark Arrestor6. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves.7. Lightly tap on the exha

104MAINTENANCEPVT SystemDo not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. T

105MAINTENANCEPVT SystemWhen To Use Low Range and High RangePVT DryingThere may be some instances when water is accidently ingested into the PVT syste

106MAINTENANCERecoil Housing (if equipped)Always drain the recoil housing after operating the vehicle in wet conditions. Drain the housing before stor

107MAINTENANCEBatteryImproperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing

9SAFETYOperator SafetyAlways inspect your POLARIS vehicle before each use to verify that it's in safe operating condition. Follow the inspection

108MAINTENANCEBatteryBattery Removal1. Place the transmission in PARK.2. Remove the seat.3. Disconnect the battery hold-down strap. 4. Remove the batt

109MAINTENANCEBatteryBattery Installation1. Ensure that the battery is fully charged.2. Place the battery in the battery holder.3. With conventional b

110MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure

111MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electrol

112MAINTENANCEBatteryBattery Charging (Sealed Battery)For a refresh charge, follow all instructions carefully.1. Check the battery voltage with a volt

113MAINTENANCECleaning and StorageWashing the VehicleKeeping your POLARIS vehicle clean will not only improve its appear-ance but it can also extend t

114MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

115MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life an

116MAINTENANCECleaning and StorageStorage TipsStarting the engine during the storage period will disturb the protective film created by fogging and da

117MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beg

10SAFETYOperator SafetyIf the vehicle has been involved in an accident, always have an authorized POLARIS dealer inspect the entire vehicle for possib

118MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Per

119MAINTENANCETransporting the VehicleFollow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in PARK.3. Se

120SPECIFICATIONS* Based on EU Directive 76/432/ECSPORTSMAN Forest 500Maximum Weight Load Capacity 485 lbs. (220 kg) (operator, cargo, accessories)Dry

121SPECIFICATIONSJetting ChartClutchingSPORTSMAN Forest 500Transmission and Gears High/Low/Neutral/Reverse/ParkingDriving System Type Automatic PVT (P

122POLARIS PRODUCTSPart NumberDescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil

123TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionDriving onto a pickup or tall trailer in high rangeUse low range.Starting out going up a

124TROUBLESHOOTINGEngine Does Not RotateEngine Rotates, Fails to StartEngine BackfiresPossible Cause SolutionTripped circuit breaker Reset the breaker

125TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

126TROUBLESHOOTINGEngine Stops or Loses PowerEngine OverheatingPossible Cause SolutionOut of fuel Refuel, cycle key to ON position three times for 5 s

127DECLARATION OF CONFORMITYPOLARIS Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500We, POLARIS Industries Inc., declare th

11SAFETYOperator SafetyAlways follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never ba

128WARRANTYLIMITED WARRANTYPOLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the POLA

129WARRANTYLIMITATIONS OF WARRANTIES AND REMEDIESWarranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and

130WARRANTYLIMITATIONS OF WARRANTIES AND REMEDIESThis warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not com

131MAINTENANCE LOGPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

132MAINTENANCE LOGDATE KILOMETERSOR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

133MAINTENANCE LOGDATE KILOMETERSOR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

134INDEXAAccessories . . . . . . . . . . . . . . . . . . 118Age Restrictions. . . . . . . . . . . . . . . . . 5Air Filter . . . . . . . . . . .

135INDEXFFoot Brake. . . . . . . . . . . . . . . . . . . . . 38Footwell Removal. . . . . . . . . . . . . . . 88Front Gearcase . . . . . . . . . . .

136INDEXRRecoil Housing . . . . . . . . . . . . . . . 106Recoil Starter . . . . . . . . . . . . . . . . . . 43Reverse Operation . . . . . . . . .

12SAFETYOperator SafetyAlways follow the procedures outlined in this manual for driving in reverse. See page 31.Always use the size and type of tires

13SAFETYOperator SafetyNever operate the vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick t

14SAFETYSafety Labels and LocationsWarning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label

15SAFETYSafety Labels and Locations“No Passenger” WarningWARNING - NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEV

16SAFETYSafe Riding GearAlways wear protective clothing to reduce the chance of injury.HelmetAlways wear a helmet that meets or exceeds established sa

17SAFETYSafe Riding GearEye ProtectionDo not depend on eyeglasses or sunglasses for eye protection. When-ever riding a POLARIS vehicle, always wear sh

For your nearest Polaris dealer,call 1-800-POLARISor visit www.polarisindustries.comPolaris Sales Inc., 2100 Hwy 55Medina, MN 55340Phone 1-888-704-52

18SAFETYDriving SafelyDriving Procedures1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars.2. Apply the brakes.3. Star

19SAFETYDriving SafelyTurning the Vehicle1. Before turning, activate a turn signal to alert others of your inten-tions. Activate the left signal befor

20SAFETYDriving SafelyDriving on Slippery SurfacesWhenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these

21SAFETYDriving SafelyDriving Over Obstacles1. Always check for obstacles before operating in a new area. Serious injury or death can result if your v

22SAFETYDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. Avoid steep hills (25 maximum).2. Check the terrain carefu

23SAFETYDriving SafelyDriving UphillIf all forward speed is lost:Keep your weight uphill.If the vehicle begins rolling downhill, never apply engine po

24SAFETYDriving SafelyDriving on a Sidehill (Sidehilling)Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, fol

25SAFETYDriving SafelyDriving DownhillWhen driving downhill, follow these precautions:1. Check the terrain carefully.2. Avoid hills with excessively s

26SAFETYDriving SafelyTurning 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 tur

27SAFETYDriving SafelyTurning Around on a Hill (K-Turn)8. Lock the hydraulic parking brake. 9. Remount from the uphill side. Keep your weight uphill.1

1WELCOMEThank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an excit-ing line of ut

28SAFETYDriving SafelyDriving Through WaterFollow these procedures when driving through water:1. Check water depth and current before crossing.2. Avoi

29SAFETYDriving SafelyDriving Through WaterIf your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it,

30SAFETYDriving SafelyParking on an InclineAvoid parking on an incline. If it's unavoidable, follow these precau-tions:1. Stop the engine.2. Plac

31SAFETYDriving SafelyDriving in ReverseFollow these precautions when operating in reverse:1. Avoid backing downhill.2. Always check for obstacles or

32SAFETYDriving SafelyHauling CargoOverloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of con

33SAFETYDriving SafelyHauling CargoTowing LoadsTowing is approved OFF-ROAD ONLY. Operating this vehicle with a trailer on public roads is prohibited.

34FEATURES AND CONTROLSSwitchesMode/Reverse Override SwitchPress the switch to toggle through the speedometer display modes (except in reverse). See p

35FEATURES AND CONTROLSSwitchesMain Key SwitchEnd all electrical power to the vehicle.LIGHTS ON position turns the headlights on.Start the engine. The

36FEATURES AND CONTROLSSwitchesTurn Signal SwitchPush the toggle switch either left or right to activate the corresponding turn sig-nal light. The ind

37FEATURES AND CONTROLSMirrorsUse the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle.Throttle

2POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS Industries Inc.Copyright 2010 POLARIS Sales Inc. All information contained wi

38FEATURES AND CONTROLSFoot BrakeThe all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press

39FEATURES AND CONTROLSParking BrakeLocking the Parking Brake1. Place the transmission in PARK.2. Squeeze the brake lever toward the handlebar.3. Push

40FEATURES AND CONTROLSSteering LockLock the steering to prevent unau-thorized use or theft of the vehicle.Tip: Place the steering lock keys in a safe

41FEATURES AND CONTROLSFuel ValveThe fuel valve is located under the front storage box cover.OFF: For vehicle storage and when transporting.ON: For no

42FEATURES AND CONTROLSTransmission Gear SelectorThe transmission gear selector is located on the right side of the vehicle.H: High GearL: Low GearN:

43FEATURES AND CONTROLSRecoil Starter (if equipped)If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedu

44FEATURES AND CONTROLSAll Wheel Drive (AWD) SystemThe AWD switch may be turned on or off while the vehicle is moving. AWD will not engage until engin

45FEATURES AND CONTROLSInstrument ClusterYour vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In

46FEATURES AND CONTROLSInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. All seg-ments will

47FEATURES AND CONTROLSInstrument ClusterRider Information CenterStandard ModesUse the MODE button to toggle through the mode options. The reverse ove

3TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . .

48FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeThe wrench icon will display when the gauge is in the diagnostic mode.

49FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeBattery Voltage ScreenView this screen to check battery voltage level.

50FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeProgrammable service intervalTo enable or disable the service interval

51OPERATIONFuel SafetyGasoline is highly flammable and explosive under certain conditions.• Use extreme caution whenever handling gasoline.• Refuel wi

52OPERATIONBreak-In PeriodThe break-in period for your new POLARIS vehicle is the first ten hours of operation, or the time it takes to use the first

53OPERATIONPre-Ride ChecklistItem Remarks PageFoot brake Ensure proper operation 38Hand brake/lever travel Ensure proper operation 85Brake fluid Ensur

54OPERATIONStarting the EngineEngine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or deat

55OPERATIONStarting the Engine7. Do not press the throttle while starting the engine. Turn the ignition key past the POSITION LIGHTS ON position to en

56WINCH GUIDEThe responsibility for safe operation of the winch ultimately rests with you, the operator. Read and understand all safety precautions an

57WINCH GUIDEWinch Cable Care1. The life of a cable is directly related to the care it receives. The wire cable on a new winch (and any replacement ca

4INTRODUCTIONThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sy

58WINCH GUIDEWinch Preparation and InspectionWear heavy leather gloves whenever handling cable. Do not allow the cable to slip through your hands, eve

59WINCH GUIDEWinch RiggingTake your time when rigging and use extra caution. Improper rigging can result in injury in addition to damage to the vehicl

60WINCH GUIDEWinch OperationNOTICE: This winch is designed for intermittent use. Prolonged use may result in damage due to overheating. 1. Use common

61WINCH GUIDEWinch Operation13. Use as much cable as possible when pulling. Additional wraps of cable on the spool will significantly reduce the pulli

62EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

63MAINTENANCEPeriodic Maintenance ChartMaintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to se

64MAINTENANCEPeriodic Maintenance ChartImproperly performing the procedures marked with a  could result in component failure and cause an accident, w

65MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first. Perform these procedures more often f

66MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Kilometers Engine oil change (break-in)-

67MAINTENANCEPeriodic Maintenance Chart Perform these procedures more often for vehicles subjected to severe use.E Emission-Related Service Have an

5INTRODUCTIONFailure to follow the warnings in this manual can result in serious injury or death. This POLARIS vehicle is not a toy and can be hazardo

68MAINTENANCELubrication GuideAlways check and change fluids and lubricate greaseable compo-nents at the intervals outlined in the Periodic Maintenanc

69MAINTENANCEEngine OilOil RecommendationsAlways change the oil filter whenever changing oil.POLARIS recommends the use of POLARIS PS-4 PLUS Performan

70MAINTENANCEEngine OilOil Level1. Position the vehicle on a level surface.2. Place the transmission in PARK.3. Start the engine. Allow it to idle for

71MAINTENANCEEngine OilOil ChangeHot oil may result in serious burns. Do not allow hot oil to contact skin.1. Position the vehicle on a level surface.

72MAINTENANCEEngine OilOil Change11. Disconnect the lower oil deliv-ery hose and remove the screen fitting from the oil tank. Clean the fitting. The f

73MAINTENANCEEngine OilOil Change20. Remove the dipstick.21. Add 1.9 liters of recommended oil. If the sump is not drained, add about 1.6 liters initi

74MAINTENANCEEngine OilOil ChangeOil Pump PrimingThis priming procedure must be performed whenever the oil hose connection between the oil tank and pu

75MAINTENANCETransmission OilMaintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 122 for the part nu

76MAINTENANCETransmission OilOil Change1. Position the vehicle on a level surface.2. Place the transmission in PARK.3. Remove the fill plug.4. Remove

77MAINTENANCEFront Gearcase (Demand Drive) FluidFluid RecommendationsUse the recommended fluid. Use of other fluids may result in improper operation o

6INTRODUCTIONVehicle Identification NumbersRecord your vehicle's identification numbers and key number in the spaces provided. Remove the spare k

78MAINTENANCEFront Gearcase (Demand Drive) FluidFluid Change1. Position the vehicle on a level surface.2. Place the transmission in PARK.3. Remove the

79MAINTENANCECarburetorThis vehicle is calibrated at the factory for optimal performance at alti-tudes ranging from zero to 6,000 feet (1800 m) and te

80MAINTENANCECooling SystemAny time the cooling system has been drained for maintenance or repair, replace the coolant with a fresh mixture of antifre

81MAINTENANCECooling SystemRadiator CoolantEscaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot.1. Rem

82MAINTENANCEBrake FluidCheck brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not

83MAINTENANCEBrake FluidHand BrakeThe master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master

84MAINTENANCEBrake FluidFoot Brake1. Position the vehicle on a level surface.2. Remove the seat.3. View the fluid level in the master cylinder.4. Main

85MAINTENANCEBrakesThe front and rear brakes are hydraulic disc brakes, activated by apply-ing the foot brake. The handlebar brake is also hydraulic.

86MAINTENANCEToe AlignmentDo not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer.Use

87MAINTENANCESteering AssemblyCheck the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see

7SAFETYOperator SafetySerious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual.R

88MAINTENANCESide Panel Removal1. Remove the seat.2. Grasp the rear of the side panel near the rear cab.3. With a firm motion, pull the panel outward

89MAINTENANCEThrottle Cable FreeplayAdjust throttle cable freeplay at the handlebar.1. Locate the throttle cable adjuster at the handlebar.2. Squeeze

90MAINTENANCETiresOperating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehi

91MAINTENANCETiresWheel Removal/InstallationAlways use original equipment size and type when replacing tires. Install wheels properly.1. Position the

92MAINTENANCEAir FilterAlways clean and replace the air and breather filters at the intervals out-lined in the Periodic Maintenance Chart beginning on

93MAINTENANCEBreather Filter/HoseThe breather filter is on the hose between the engine and air box.1. Remove the left side panel. See page 88.2. Remov

94MAINTENANCELightsHeadlight Beam AdjustmentThe headlight beam can be adjusted slightly upward or downward.1. Position the vehicle on a level surface.

95MAINTENANCELightsPoor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and ta

96MAINTENANCELightsTaillight Lamp Replacement1. Place the transmission in PARK.2. Rotate the taillight socket counter-clockwise to remove it.3. Remove

97MAINTENANCEFuse ReplacementIf the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locat