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2006-2013 Sportsman 500 Oil and Filter Change

Required Tools and Supplies

  • 3/8-Inch Socket (X2 and Touring Models Only)
  • 9/16-Inch Socket
  • 7/8-Inch Wrench
  • 7/8 Crow Foot
  • Ratchet
  • Torque Wrench
  • Pliers
  • 2.5-Inch Oil Filter Wrench
  • Oil Pan
  • Funnel 
  • Locking Pliers
  • Loctite® 505 or Equivalent Pipe Thread
  • Eye Protection
  • Nitrile Gloves
  • Shop Rags

To learn more about tools, read the Tools and Fasteners Guide. When changing the oil on your ATV, always wear safety glasses and nitrile gloves. Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart in your Owner's Manual

To change the engine oil and filter on your Sportsman 500, follow these steps:

1. Park the vehicle on a flat, level surface, ensure it is in park and set the parking brake.

2. Start the engine, allow it to warm up at idle for 2 to 3 minutes and stop the engine.

3. Clean the area around the dipstick. 

4. Remove the dipstick and set it aside.

5. Place a drain pan under the engine crankcase. Tip: Placing a rag in the bottom of the drain pan will help prevent the splashing of oil.

6. Clean the area around the oil drain plug.

7. Remove the drain plug and washer with a 9/16-inch socket and allow the oil to drain completely. Approximately one cup of engine oil will remain in the crankcase that will be removed later.

8. Slide the clamp off the upper vent hose on the tank. This procedure may be difficult on X2 and Touring models and may require removal of the oil tank.

9. Remove the middle vent hose on the oil tank.

10. Note: On X2 and Touring models, the screen fitting on the tank is difficult to access. Removing the oil tank will aid in clearance.

11. To remove the oil tank, remove the oil tank fasteners with a 3/8-inch socket and pivot the tank out of the vehicle.

12. For all models, loosen the clamp on the oil hose on the bottom of the oil tank. 

13. Carefully remove the oil hose.

14. Carefully remove the screen fitting from the tank with a 7/8-inch wrench. Note: Use care when removing the fitting as the plastic tank may strip or break.

15. Clean the screen fitting while inspecting for damage or wear and replace if necessary.

16. Clean the threads on the tank and ensuring they are free of any oil or sealant.

17. Apply Loctite® 505 sealant or an equivalent pipe thread sealant to the threads.

18. Reinstall the screen fitting into the oil tank and rotate it clockwise a minimum of two and a half turns. Rotate the fitting until it aligns with the reference mark on the tank. The maximum torque is 25 ft-lbs (34 Nm). Do not over tighten.

19. Reconnect the oil hose and reposition the clamp over the fitting.

20. If previously removed, align the oil tank with the mounting holes and reinstall the fasteners.

21. Torque the fasteners to 60 in-lbs (7 Nm).

22. Reconnect the middle vent hose on the oil tank.

23. Reconnect the upper hose on the oil tank and slide the clamp over the fitting.

24. Clean any dirt or debris from the drain plug and ensure the sealing surfaces are free of any nicks or scratches. 

25. Install a new sealing washer on the drain plug. A new drain washer is part number 5850135.

26. Reinstall the drain plug, and torque to 14 ft-lbs (19 Nm).

27. Clean any residual oil off the vehicle.

28. Access the oil filter on the left side of the engine and clean any dirt or debris.

29. Place a shop rag underneath the filter to catch excess spillage.

30. Turn the filter counterclockwise with a 2.5-inch oil filter wrench to remove it.

31. Clean any residual oil off the vehicle.

32. Before continuing, remove any shop rags from underneath the oil filter.

33. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 

34. Lubricate the O-ring on the new filter with a film of fresh engine oil and ensure the O-ring is in good condition.

35. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface. Turn it an additional half of a turn. A new oil filter is part number 3084963.

36. Move to the lower right side of the crankcase to clean the area around the crankcase drain plug.

37. Remove the crankcase drain plug and allow the oil to fully drain.

38. Clean any dirt or debris from the drain plug and ensure the sealing surfaces are free of any nicks or scratches.

39. Install a new sealing washer on the drain plug. A new drain washer is part number 3082956.

40. Reinstall the drain plug, and torque to 14 ft-lbs (19 Nm) with a 7/8 crow foot.

41. Fill the engine with the proper amount of the recommended oil through the oil dipstick port. Do not overfill. One gallon of PS-4 Synthetic Oil is part number 2877473. One quart of PS-4 Synthetic Oil is part number 2876244. The maximum capacity is 2 quarts (1.9 L)

42. Reinstall the dipstick and wipe up any residual oil.

43. Clamp or pinch off the vent line two inches from the oil tank to prime the engine. If necessary, refer to the Oil Pump Priming Procedure in your Owner’s Manual for more information.

44. Start the engine and allow it to idle for ten to fifteen seconds.

45. Stop the engine and inspect for any leaks. 

46. Remove the vent line clamp.

47. Remove the dipstick and wipe with a clean shop towel. Reinstall the dipstick fully and remove again to inspect the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.

48. Reinstall the dipstick and wipe up any residual oil.

49. Dispose of the used oil and filter properly at your local recycling center.

50. Grease the grease zerks on the front and rear A-arms with All Season Grease and on the front prop shaft with U-Joint Grease.

51. To reset the service interval:

  • Ensure the key has been switched off for at least 10 seconds.
  • Ensure the parking brake is set.
  • Place the transmission in neutral.
  • Hold the mode/reverse override button and turn the key switch on and release the switch as soon as the display is activated.
  • Use the mode button to toggle to the service interval screen.
  • Press and hold the mode button for two to three seconds until the wrench icon flashes. Then release the button.
  • Continue by pressing and releasing the mode button once to advance the setting by one hour. Press and hold the mode button to advance the hours quickly.
  • Once the desired setting is displayed, wait until the wrench icon stops flashing, and the new interval will be set.

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

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