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Polaris · Overhead-cam four-stroke single, wet sump, gearbox shares engine oil, shaft drive

Sportsman 500

Library entry covers 2010-2024

47 factory 52 guideline

Published source

2013 Polaris Sportsman 400/500 HO Owner's Manual, Periodic Maintenance Chart pp.64-66 (archive.org copy)

Factory owner's handbook. Covers 2013 Polaris Sportsman 400/500 HO owner's manual (P/N 9923790).

99 items for a 2012 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)
Engine cycle
Four-stroke
Engine lubrication
Wet sump (oil in crankcase)
Oil filtration
Replaceable cartridge or spin-on filter
Valve gear
Overhead cam, screw/locknut adjusters
Ignition
Electronic (CDI / transistor / ECU)
Charging
Alternator / stator with rectifier
Battery
Wet cell (flooded lead-acid, needs topping up)
Fuel system
Single carburetor
Cooling
Liquid cooled
Primary drive
Gear or chain inside engine, shares engine oil
Gearbox oil
Shares engine oil
Clutch control
Automatic or semi-automatic
Final drive
Shaft
Front suspension
Telescopic fork
Rear suspension
Swingarm, twin shocks
Front brake
Disc, hydraulic
Rear brake
Drum (or band / belt rim)
Wheels
Spoked, tubed
Sidecar
No sidecar
Maintenance schedule

2012 Polaris Sportsman 500

On the road: every 200 mi

1 item
  • Check engine oil level
    Pre-ride / on the road
    Guideline

    Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items
  • Check lights, horn, brake light switches
    Pre-ride / on the road
    Guideline
  • Check tire pressures
    Pre-ride / on the road
    Guideline

On the road: every 500 mi

1 item
  • Check coolant level
    Pre-ride / on the road
    Guideline

Every 10 h or 100 mi or 1 month

1 item
  • Brake pad wear
    Brakes
    Factory

    Factory: Whichever comes first. Monthly: inspect periodically. Dealer service

Every 20 h or 200 mi or 1 month

1 item
  • Battery
    Ignition and electrics
    Factory

    Factory: Whichever comes first. Monthly: check terminals; clean; test

Every 25 h or 250 mi or 1 month

1 item
  • Engine breather filter (if equipped)
    Engine
    Factory

    Factory: Whichever comes first. Monthly: inspect; clean if needed. Emission-related

Every 50 h or 500 mi or 3 months

1 item
  • General lubrication
    Engine
    Factory

    Factory: Whichever comes first. Lubricate all fittings, pivots, cables, etc.

Every 50 h or 500 mi or 6 months

5 items
  • Drive belt
    Engine
    Factory

    Factory: Whichever comes first. Inspect; adjust; replace as needed

  • Carburetor air intake ducts/flange
    Fuel and air
    Factory

    Factory: Whichever comes first. Inspect duct for proper sealing/air leaks. Emission-related

  • Carburetor float bowl
    Fuel and air
    Factory

    Factory: Whichever comes first. Drain bowl periodically and prior to storage

  • Choke cable
    Controls and cables
    Factory

    Factory: Whichever comes first. Inspect; adjust; lubricate; replace if necessary. Dealer service; emission-related

  • Throttle cable/release switch
    Controls and cables
    Factory

    Factory: Whichever comes first. Inspect; adjust; lubricate; replace if necessary. Dealer service; emission-related

Every 1,000 mi or 6 months

2 items
  • Adjust rear drum brake and rod / cable linkage
    Brakes
    Guideline
  • Inspect tire tread, sidewalls and date codes
    Wheels and tires
    Guideline

Every 50 h or 1,000 mi or 6 months

1 item
  • Cooling system
    Engine
    Factory

    Factory: Whichever comes first. Inspect coolant strength seasonally; pressure test system yearly

Every 100 h or 1,000 mi or 6 months

1 item
  • Engine oil change
    Engine
    Factory

    Factory: Whichever comes first. Break-in: oil and filter change at 25 H, 1 M or 250 mi (400 km). Change the oil and filter

Every 100 h or 1,000 mi or 12 months

14 items
  • Demand drive fluid (normal use)
    Engine
    Factory

    Factory: Whichever comes first. Break-in: oil level check at 25 H, 1 M or 250 mi (400 km). Change fluid

  • Engine mounts
    Engine
    Factory

    Factory: Whichever comes first. Inspect

  • Exhaust muffler/pipe
    Engine
    Factory

    Factory: Whichever comes first. Inspect

  • Rear gearcase oil
    Engine
    Factory

    Factory: Whichever comes first. Break-in: oil level check at 25 H, 1 M or 250 mi (400 km). Change fluid

  • Spark plug
    Engine
    Factory

    Factory: Whichever comes first. Inspect; replace as needed. Dealer service; emission-related

  • Valve clearance
    Engine
    Factory

    Factory: Whichever comes first. Inspect; adjust. Dealer service; emission-related

  • Wiring
    Engine
    Factory

    Factory: Whichever comes first. Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

  • Fuel system/filter
    Fuel and air
    Factory

    Factory: Whichever comes first. Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years. Dealer service; emission-related

  • Ignition timing
    Ignition and electrics
    Factory

    Factory: Whichever comes first. Inspect. Dealer service; emission-related

  • Clutches (drive and driven)
    Primary and gearbox
    Factory

    Factory: Whichever comes first. Inspect; clean; replace worn parts. Dealer service

  • Transmission oil
    Primary and gearbox
    Factory

    Factory: Whichever comes first. Break-in: oil level check at 25 H, 1 M or 250 mi (400 km). Change fluid

  • Front wheel bearings
    Wheels and tires
    Factory

    Factory: Whichever comes first. Inspect; replace as needed. Dealer service

  • Cooling hoses (if applicable)
    Controls and cables
    Factory

    Factory: Whichever comes first. Inspect for leaks

  • Radiator (if applicable)
    Controls and cables
    Factory

    Factory: Whichever comes first. Inspect; clean external surfaces

Every 200 h or 2,000 mi or 2 years

1 item
  • Brake fluid
    Brakes
    Factory

    Factory: Whichever comes first. Change every two years. Dealer service

Every 3,000 mi or 12 months

10 items
  • Check throttle cable(s) free play and return
    Fuel and air
    Guideline
  • Clean fuel tap filter / sediment bowl
    Fuel and air
    Guideline
  • Adjust automatic / semi-automatic clutch
    Primary and gearbox
    Guideline
  • Check steering head bearing adjustment
    Front end
    Guideline
  • Inspect fork seals, stanchions and fork boots
    Front end
    Guideline
  • Check footrests, pegs, rear brake and gear lever pivots
    Rear suspension and frame
    Guideline
  • Grease and check center / side stand and springs
    Rear suspension and frame
    Guideline
  • Check brake pads and discs
    Brakes
    Guideline
  • Check spoke tension and wheel true
    Wheels and tires
    Guideline
  • Check wheel bearings for play
    Wheels and tires
    Guideline

Every 300 h or 3,000 mi or 3 years

1 item
  • Spark arrester
    Engine
    Factory

    Factory: Whichever comes first. Clean out

Every 4,000 mi or 12 months

2 items
  • Inspect, clean and gap spark plugs
    Engine
    Guideline
  • Lubricate brake cam spindles, check linings and drums
    Brakes
    Guideline

Every 5,000 mi or 12 months

2 items
  • Change engine oil
    Engine
    Guideline

    Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.

  • Replace oil filter
    Engine
    Guideline

Every 6,000 mi or 12 months

9 items
  • Inspect coolant hoses and clamps
    Engine
    Guideline
  • Clean / inspect air filter
    Fuel and air
    Guideline

    Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.

  • Clean carburetor float bowl(s), check float level and jets
    Fuel and air
    Guideline

    Ethanol fuel varnishes old carbs quickly in storage.

  • Check charging voltage and regulator / cut-out
    Ignition and electrics
    Guideline
  • Check final drive for leaks and bearing play
    Final drive
    Guideline
  • Check swingarm bushes for play
    Rear suspension and frame
    Guideline
  • Inspect rear shocks for leaks and damping
    Rear suspension and frame
    Guideline
  • Lubricate control cables and lever pivots
    Controls and cables
    Guideline
  • Lubricate speedometer / tachometer cables, check drive
    Controls and cables
    Guideline

    A dry speedo cable whips the needle and eventually kills the instrument.

Every 8,000 mi or 2 years

1 item
  • Check and adjust valve clearances
    Engine
    Guideline

Every 10,000 mi or 2 years

1 item
  • Compression test (or leak-down)
    Engine
    Guideline

Every 12,000 mi or 2 years

3 items
  • Replace air filter element
    Fuel and air
    Guideline
  • Change final drive (rear drive) oil
    Final drive
    Guideline
  • Grease swingarm pivot
    Rear suspension and frame
    Guideline

Every 15,000 mi or 3 years

1 item
  • Change fork oil
    Front end
    Guideline

    Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi

1 item
  • Replace brake linings / skim drums (wear based)
    Brakes
    Guideline

Every 16,000 mi or 4 years

1 item
  • Replace spark plugs
    Engine
    Guideline

Every 20,000 mi or 4 years

3 items
  • Lubricate drive shaft splines / check U-joint
    Final drive
    Guideline
  • Repack / replace steering head bearings
    Front end
    Guideline

    Many old machines use loose balls in cups and cones. Taper roller conversions are common.

  • Repack / replace wheel bearings
    Wheels and tires
    Guideline

    Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item
  • Replace swingarm bushes / bearings
    Rear suspension and frame
    Guideline

Every 30,000 mi or 6 years

1 item
  • Rebuild forks: seals, bushes, springs
    Front end
    Guideline

Every 6 months

1 item
  • Clean battery terminals, check charge and strap
    Ignition and electrics
    Guideline

Every 2 years

5 items
  • Coolant (change)
    Engine
    Factory

    Factory: Change coolant every 2 years

  • Replace coolant
    Engine
    Guideline
  • Inspect wiring, bullet connectors and ground points
    Ignition and electrics
    Guideline
  • Inspect frame, welds and lugs for cracks
    Rear suspension and frame
    Guideline
  • Replace brake fluid
    Brakes
    Guideline

Every 4 years

3 items
  • Replace fuel lines
    Fuel and air
    Guideline

    Old rubber and modern ethanol fuel do not mix well.

  • Inspect brake hoses; replace old rubber
    Brakes
    Guideline
  • Rebuild calipers and master cylinders (seals)
    Brakes
    Guideline

Every 6 years

2 items
  • Replace inner tubes and rim tape with tires
    Wheels and tires
    Guideline
  • Replace tires on age (regardless of tread)
    Wheels and tires
    Guideline

No interval set

19 items
  • Air box sediment tube
    Engine
    Factory

    Factory: Daily: drain deposits when visible

  • Coolant (check level)
    Engine
    Factory

    Factory: Daily: check level

  • Engine oil level
    Engine
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

  • Front suspension
    Engine
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

  • Headlight aim
    Engine
    Factory

    Factory: Adjust as needed

  • Headlight/taillight/worklight
    Engine
    Factory

    Factory: Daily: check operation; apply dielectric grease if replacing lamps

  • Idle speed
    Engine
    Factory

    Factory: Adjust as needed

  • Rear suspension
    Engine
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

  • Recoil housing
    Engine
    Factory

    Factory: Weekly: drain water as needed, check often if operating in wet conditions

  • Toe adjustment
    Engine
    Factory

    Factory: Inspect periodically; adjust when parts are replaced. Dealer service

  • Air filter, main element
    Fuel and air
    Factory

    Factory: Weekly: inspect; replace as needed. Emission-related

  • Air filter, pre-filter
    Fuel and air
    Factory

    Factory: Daily: inspect; clean often; replace as needed. More often for severe use. Emission-related

  • Steering
    Front end
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

  • Frame fasteners
    Rear suspension and frame
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

  • Brake fluid level
    Brakes
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

  • Brake lever travel
    Brakes
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

  • Brake system
    Brakes
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

  • Tires
    Wheels and tires
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

  • Wheels/fasteners
    Wheels and tires
    Factory

    Factory: Pre-ride. Make adjustments as needed; see Pre-Ride Checklist

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

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