Polaris Scrambler 500 2X4 International Bedienungsanleitung

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P antone 425 C W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without pr oper training or instruction. S at speeds too fast for your skills or the conditions. S on public r oads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steering and incr ease risk of los[...]

1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • Quadricycles • RANGER utility vehicles • V ictory motorcycles Always follow the instructions and recommen[...]

2 POLARIS and POLARIS THE W A Y OUT are registere d trademarks of Pol aris Indus - tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production compo nents, some minor discre[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F e atures and Controls . . . . . . . . . . . . . . . . . . . 22 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Emission Control Systems . . . . . . . . . . . [...]

4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety ale rt symbol indicates a potentia l personal injury hazard. W ARNING A W ARN ING indicates a hazardo[...]

5 INTRODUCTION Failure to hee d the warnin gs and safety precaution s contained in this manu al can result in severe injury or death. This vehicle is not a toy and ca n be hazardous to operate. A collision or ro llover can occur quickly , even during routine maneuvers, if you fail to take proper precautions. • Read this ow ner ’s manual. Unders[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key number in the spaces provided. Remove the spare ke y and store it in a safe place. The ignition switch must be replaced if all keys are lost. V ehicle Model Number: ____________________________________ _______________ F rame VIN: ___ __________[...]

7 SAFETY Safety T raining When you purcha sed your new Polaris v ehicle, your dealer o f fered a hands-on safety traini ng course. Y ou were also provi ded with printed materials that explain sa fe operatin g procedures. Review this informa- tion on a regular basis. If you purchased your vehicle from a party other than a Polaris dealer , please req[...]

8 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury . Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Ca na da bear a U.S. Department of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE ma[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equ i pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make s[...]

10 SAFETY Operator Safety Failure to ope rate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owne r ’s manual. See the OPERA TION section of the owner ’ s manual fo r proper operating procedures. Read and[...]

11 SAFETY Operator Safety Handling Gasoline Gasoline is h ighly flammable and explosive under certain conditions. • Always exercise extreme cautio n whenever hand ling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling [...]

12 SAFETY Operator Safety Never consume alcoho l or drugs before or while operating this vehicle. Keep both h ands on the ha ndlebars. Keep both feet on the footrests. Never carry a passenger . Th e purpose of the long se at is to allow the operator to shift position as needed during ope ration. It is not intended for carrying passengers.[...]

13 SAFETY Operator Safety Never carry a passenger on the rear rack. Ejection from the vehicle or contact with moving component s can result in serious injury or death. Operating on paved surfaces may serious ly affect the handling and control of the Quadricycle and could result in loss of control, acci dent and/or injury . A void sudden turns o r s[...]

14 SAFETY Operator Safety Always follow the procedures ou tlined in this manual for turning. Never turn sha rply at excessive speeds, which can lead to vehicle overturn. See page 37. Never attempt jumps or other stunts. Always follow the procedures ou tlined in this manual for driving th rough wate r . Never drive through deep or fast-flowing water[...]

15 SAFETY Operator Safety Always follow the procedures ou tlined in this manual for driving on hills. See page 39. Never operate on hills too steep for this vehicle or for your abilities. Practice on smaller hills b efore attempting larg er hills. Avoid climbing hills steeper than 25 ° . Always follow the procedures ou tlined in this manual for dr[...]

16 SAFETY Operator Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure . Always travel slowly when ope rating on unfamiliar terra in. Use extra caution. Always follow the procedures outl ined in this manual for driving in reverse. See pa ge 45. Use caution when o perating on rough, slippery or [...]

17 SAFETY Operator Safety Never operate this vehicle on a frozen body of wa ter . Never modify a Quadricycle through imprope r installation or use of accessories. Never exceed the stated load cap acity fo r your vehicle. Cargo must b e properly distributed and securely attached. Reduce spee d and follow the instructi ons in this manual for carrying[...]

18 SAFETY Safety Labels and Locations W arning labe ls have been placed on the vehicle for your protec tion. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual dif fer from the la bels on your vehicle , always read and follow the instructio ns of the labels on the vehicle. If an informational or gr[...]

19 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper than 25 degrees 25 ° . T o pre- vent overturn on hilly terrain, use throttle and brakes gradually , and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. S teering becomes difficult. T o prevent loss of c[...]

20 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a p assenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 T ire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or death.[...]

21 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you are under the ag e of 16 increases your chance of severe injury or d eath. NEVER operate this A TV if you are under age 16. 7175374 Clutch Cover W arning W ARNING • Moving part s hazard und er belt-clutch gu ard. T o p revent serious injury , do not operate [...]

22 FEA TURES AND CONTROLS Switches Override Switch This vehicle is equipped with a re verse sp eed limiter system. T o gain additional wheel speed while backing, release the throttle and press the override switch. W ARNING! Pressing the override switch while the throttle is open can cause loss of control, wh ich may result in seri ous injury or dea[...]

23 FEA TURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn th e lights on and of f and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. Indicator Light s W ith the engine running, verify the function of all [...]

24 FEA TURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine sp eed and vehicle movement. Failure to check or ma intain proper operation o f the throttle system can resul t in an accident if the thrott le lever sticks during opera tion. Check the lever for proper[...]

25 FEA TURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handleb ar to apply the fron t and rear brakes. These brakes are hyd raulically activated d isc type br akes that a re activated by only one lever . Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any spo[...]

26 FEA TURES AND CONTROLS Parking Brake 1. Place the transmission in gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lock, squeez e and release the brake lever . It will return to its unlo[...]

27 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary r ear brake when backing down a hill may cause rear tipover , which could result in serious injury or death. Never back down a hill. Use caution when applying the a uxiliary brake. Do not aggressively a pply the auxiliary brake when going forward. The rear wheels ma[...]

28 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 34 for correct ch oke and throttle settings during start- ing. Fuel T ank Cap Always refuel with the engine stopped, and outdoo rs or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel t[...]

29 FEA TURES AND CONTROLS T r ansmission Gear Selector The transmission gear selector is located on the right side of the vehicle. F: Forward Gear N: Neutral R: Reverse T o shift gears, brake to a complete stop. When the engine is id ling, move the lever to the desired gear . NOTICE: Shifting gears with the engine speed above idle or while th e veh[...]

30 OPERA TION Failure to ope rate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death . Read and understand all safety warnings outlined in the safety section of this owner ’ s manual. Break-In Period The break-in p eriod for your new Polaris vehicle is the first ten h[...]

31 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 28. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 56. Add oil as n eeded to maintai n the level in the proper range. 3. Drive slowly at first. Select an op en area t hat allows room to famil- iari[...]

32 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training be fore operating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicl e. 3. Never carry a pa ssenger on th is vehicle. 4. Engine ex h[...]

33 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 25 64 Brake fluid En[...]

34 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in neutral. 3. Lock th e parking br ake. Tip : The starter interlock will prevent the eng ine from starting if the transmissi on is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. Si[...]

35 OPERA TION S t arting the Engine 9. T urn the ignition key past the ON position to engage t he starter . Activate the starter for a maximum of five seconds, releasing the key when the en gine starts. NOTICE: Operating the vehicle immediate ly after st arting could cause engine damage. Allow the engine to warm up for several minutes before operat[...]

36 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright. Keep your feet o n th e footrests. Keep both hands on the handlebars. 3. Squeeze the brake lever . 4. S tart the engine and allow it to warm up. 5. Shift the transmission into gear . 6. Check you r surroundings and determine your path of travel. 7. Re[...]

37 OPERA TION T urning the V ehicle T o turn, steer in the direction of the turn, leaning your upper body to the inside of the turn wh ile supporting you r weight on the outer fo otrest. The same leaning technique should be used for turn ing in reverse. Practice making turns at s low speeds before attempting to turn at faster speeds. T urning impro[...]

38 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezin g weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas. 3. Maintain a high level of alertne ss, reading the trail and avoi[...]

39 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure cou ld cause loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Always check the ter- rain carefully before ascending an[...]

40 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proced ure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void hills with excessively slippery or loos[...]

41 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. A void hills with excessively slippery or loose surfaces. 3. Shift body weight uph ill. 4. Drive straight downhill. 5. Slow down. Never go down a hill at high speed. 6. A void going down a hill at an angle, which can cause the v[...]

42 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the p arking brake while keeping body weight up hill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hi cle, or on the le[...]

43 OPERA TION Driving Through W ater Y our Polaris vehicle can operate through water with a maximum recom- mended dep th equal to the botto m of the footrests. Follow these proce- dures when operating through water: 1. Determine water depths and cu rrent before entering water . 2. Choose a crossing where both banks have gradual inclines. 3. A v oid[...]

44 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Be alert. W atch the terrain. Use extra caution 3. Never operate over large obstacles. 4. A void hazards such a s logs, rocks and low branches.[...]

45 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or peop le behind the vehicle. 2. Always avoid ba cking downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override switch unl[...]

46 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to wing cargo improperl y can alte r vehicle handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these p recautions when hauling carg o: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO.[...]

47 OPERA TION Hauling Cargo Load Distribution Accessory racks and hitches are available from your Polaris dealer . Read and understand the lo ad distribu- tion warni ngs listed on the vehicle warning labels. Never exceed the specified weights. Carg o weight sh ould be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted a[...]

48 OPERA TION Parking on an Incline A void parking on an incline. If it' s unavoidable, follow these precau- tions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock th e parking br ake. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve off.[...]

49 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with gover nmental noise level requirements. Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel de livery and igni[...]

50 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio n, adjustment and lubrication of important components are explained in the periodic ma intenance ch art. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

51 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a  could re sult in component failure and cause an accid ent, wh ich may resu lt in serious injury or death. Always have an authorize d Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subjec[...]

52 MAINTENANCE Periodic Maintenance Chart Perform all services at whiche ver main tenance interval is r eached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Cale[...]

53 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Engine oil change (break-in) 25 1 M 250 (400) P erform a break-in oil change X General lubrication 50 3 M 500 (800) Lubricate all fittings, pivots, cables, etc. Carburetor float bowl 50 6 M 500 (800) Drain bowl periodica[...]

54 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Exhaust muffler/ pipe 100 12 M 1000 (1 600) Inspect Q E Spar[...]

55 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 50. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS P erformance Synthetic 2W -50 See page 56. Brake Fluid DOT 4 Only See pa[...]

56 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for thi s engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's re commendatio ns for ambient tempera- ture operatio[...]

57 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 50. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine. 2. [...]

58 MAINTENANCE Oil and Filter Change 8. Place towels under the oil filter . Using an oil filter wrench, turn the filter counterclockwise to remove it. 9. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Make sure the gasket from the old filter is not still on the engine. 10. I[...]

59 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be performed when ever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pin ch off the vent line approximately two inches (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pres[...]

60 MAINTENANCE T r ansmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 50. Maintain the oil level within the SAFE oper ating range on the dipstick. T ransmission Oil Recommendations Oil Check 1. Position the vehicle on a level surface. 2. The transmission oil dip[...]

61 MAINTENANCE T r ansmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan beneath the transmission oil drain plug area. 3. Loosen the jam nut. 4. T urn the adjuster bolt in to allow the removal of the drain plug. 5. Remove the d rain plug and wipe the magnetic end clean to remove accumulated metallic filings. 6. [...]

62 MAINTENANCE Brakes Brake Fluid An over-full master cylinder may cause brake drag or br ake lock-up, which co uld result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Once open, a bottle of br ake fluid absorb s moisture from the air , which ca uses the boiling temperature of the brake flui d to drop. This can le[...]

63 MAINTENANCE Brakes Brake Fluid (Hand Brake) Check the brake fluid level in the master cylinder before each u se of the vehi cle. The maste r cylinder is located on the left handlebar . Maintain the fluid level 1/4" (6 mm) below the top edge of the master cylinder . Do not overfill. 1. Position the vehicle on a level surface. Make sure the h[...]

64 MAINTENANCE Brakes Brake Check Perform the followin g checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily during normal opera- tion. 1. Always keep foot brake flu id at an adequate level. Check the foot brake system regularly for fluid leaks. 2. Check the brakes for excessive travel or spongy[...]

65 MAINTENANCE T o e Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent is 3-6 mm toe out. W ARNING! Severe injury or death can result from improper to e alignment and adjustment. Do not attemp t to adjust ti e rod alignment. Al l tie rod adjustments should be performed by an auth orized [...]

66 MAINTENANCE S teering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and b olts are found, see your Polaris dealer for service before operating the vehicle. Rear Suspension The rear suspension spring preload and shock compression damping may be adjusted to suit dif ferent riding condi- ti[...]

67 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Slide the boots of f the inline cable adjuster sleeve. Loosen the adjuster locknut. 2. T urn the adju ster until 1.6-3 mm of freeplay exists at the lever . Move the throttle lever back and forth several times while adjusting. 3. T ighten the lock nut and sli[...]

68 MAINTENANCE Handlebars W ARNING! Improper adjustme nt of the handleba rs or incorrect torqui ng of the adjuster block tightenin g bolts can caus e limited steeri ng or loosening of the handlebars, resulti ng in loss of control and serious injury or death. Follow the adjustment procedures exactly , or see your Polaris dealer fo r service. The han[...]

69 MAINTENANCE Carburetor Y our Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or highe r . Above 1800 me ters the engine air/fuel mixture becomes too rich and the engine lo ses approximately 3% of its powe r for each 300 meter incr ease in eleva[...]

70 MAINTENANCE Drive Chain Drive Chain Lubrication The drive ch ains are equip ped with o-ring-sealed, permanently greased pins and rollers. Howe ver , the outer surfaces of the roller must be lubri- cated. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or dama ged rollers. Also check for correct[...]

71 MAINTENANCE Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three dif ferent locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at th e tightest of the three positions. At this point the chain should have 3/16" -3/8" (5 mm - 10 mm) deflection. [...]

72 MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or back- ward to adjust the chain slac k to the proper tension. See the illustration for proper splice link clip opening position . 7. T ighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch and 45 ft. lbs. (61 Nm) for machines with a hi[...]

73 MAINTENANCE Cooling System The engin e coolant leve l is controlled, or main tained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases , the expa nding (heated) excess coolant is forced out of th[...]

74 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to prot ect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair . If the recov[...]

75 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and rep lace burned out lamps promptly . Always make sure lights are adjusted properly for best visibility . Headlamp Replacement When servicing a ha logen lamp, don't[...]

76 MAINTENANCE Light s T aillight/Brakelight Lamp Replacement 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly . 2. Remove the lamp. 3. Apply dielectric grease to the socket and install the new lamp. 4. T est the taillight/brake light for proper operation. 5. Reinstall the gasket and [...]

77 MAINTENANCE Ti r e s Operating your veh icle with worn tires, improperl y inflated tires, non-standard tires or impro perly installed tires will affect vehicle h andling and could cause an accident resulting in serious injury or death . Always follow all tire maintenance procedures as outlined in this manua l a nd on the labels on the vehicle. A[...]

78 MAINTENANCE Ti r e s Wheel Removal 1. Position the vehicle on a level su rface. Place the tr ansmission in gear . Lock the parking brake. 2. Loosen the wheel nuts slightly . 3. Safely place jackstands under the vehicle. 4. Remove the wheel nut s. Remove the wheel. Wheel Inst allation 1. Place the wheel on the wheel hub with the valve stem toward[...]

79 MAINTENANCE Ti r e s Wheel Nut T orque Specifications Check the wheel nut torques occasional ly and when they 've been loos- ened for service. Item T orque Spe cification F ront Wheel Nuts 27 ft. lbs. (37 Nm) Rear Wheel Nuts 50 ft. lbs. (68 Nm) Rear 50 ft. lbs. (68 Nm) Fr o n t 27 ft. lbs. (37 Nm)[...]

80 MAINTENANCE Air Filter 1. Position the vehicle on a level su rface. Place the tr ansmission in gear . Lock the parking brake. 2. Remove the seat. 3. Release the air box cover clips, and remove the air box cover . 4. Loosen the clamp and remove the filter . 5. Remove the pre-filter from the main filter . 6. W ash the pre-filter in soapy water , t[...]

81 MAINTENANCE Breather Filter 1. Remove the clamps and pull the breather filter out of the hoses. It's not necessary to remove the lower hose from the engine. 2. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clog ging. Replace if needed. 3. Check the hoses for cracks, deterioration, a[...]

82 MAINTENANCE Spar k P l u g s S p ark Plug Recommendations Refer to the specifi cations section beginning on page 102 for the recom- mended spark pl ug type and gap for you r vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plugs. S p ark Plug Inspection Check the spark [...]

83 MAINTENANCE Spar k P l u g s S p ark Plug Condition Normal Spar k Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and wh ite. A white insulator ti[...]

84 MAINTENANCE V ehicle Immersion If the vehicle stops while fully submerged, major engine dama ge can result if the machine is not thor oughl y inspected. T a ke the vehicle to your dealer before startin g the engine. If it's impossible to take your vehicle to a dealer before starting it, fol- low the steps outlined below . 1. Move the vehicl[...]

85 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warnings while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combusti ble materials from the a rea. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Ne[...]

86 MAINTENANCE P VT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce i ts strength so that a failure ma y occur at a high speed. The PVT system has be en precision balanced. Any modi fication will cause the system to be out of bal[...]

87 MAINTENANCE P VT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt. Similarly , if the engine speed de[...]

88 MAINTENANCE P VT System P VT Drying There may be some instances w hen wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Move the vehicle out of the water . 2. Remove the PVT drain plug. Allo w the water to drain completely . Reinstall the drain plug. 3. S tart the engine. Place[...]

89 MAINTENANCE Battery Improperly connecting or discon necting battery cables can resul t in an explosion and cause serious injury or death. When removing the battery , alw ays disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisono us. It contains [...]

90 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock th e parking br ake. 3. Disconnect the battery hold-down strap. 4. Remove the battery cover . 5. On conventional batteries, re move the battery vent tube. 6. Disconnect the black (negative) battery cable first. 7. Disconnect the red (positive) battery cable last. 8. [...]

91 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinder vehicle performance. Follow the battery char ging instructio ns on page 93 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in [...]

92 MAINTENANCE Battery Batter y S torage 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 char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recha r ge as needed to mainta in a full charge. Tip : Power[...]

93 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled ele ctrolyte during cha r ging. Se e page 90. 2. Char ge the battery with a charging output no lar ger than 1/10 of the battery’ s amp/hr rating. Char ge as needed to ra ise the specific grav- ity to [...]

94 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top o f battery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-10[...]

95 MAINTENANCE Cleaning and S torage W ashing th e V ehicle Keeping the vehicle clean will ex tend the life of components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surface[...]

96 MAINTENANCE Cleaning and S torage W ashing the V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution. The wa ter may da mage components. A void directing the water stream at the following items: If an informational or graphic label becomes illegible or comes of f, con- tact your Polaris dealer[...]

97 MAINTENANCE Cleaning and S torage 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 ye ars. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. C lean ch[...]

98 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps NOTICE: S tarting the engine during the storage perio d will disturb the protective film created by fogging and damage could occur . Never start the engine during the stora ge period. Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. See page 95. Stabilize the[...]

99 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Fluid Levels Inspect the fluid levels. Chan ge fluids as reco mmended in the Pe riodic Maintenance Chart beg inning on page 50. • T ransmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) F og the Engine 1. T reat[...]

100 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Inspect and Lubricate Inspect all cables a nd lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 50. Battery Storage See page 92-94 for sto rage and char ging procedures. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. [...]

101 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock th e parking br ake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to preven t loss during transporting. 7. Always tie the frame of the vehicle [...]

102 SPECIFICA TIONS * Based on EU Directive 76/432/EC Scrambler 500 2X4 Maximum W eight Capacity 305 lbs. (138 kg) (includes weight of opera- tor , car go and accessories) Dry W e ight 530 lbs. (240 kg) Fuel Capacity 3.5 gal. (13.2 l) Engine Oil Capacity 2 qts. ( 1.9 l) T ransmission Oil 1 1.3 oz. (334 ml) Coolant 2.25 qts. (2.13 l) Front Rack Capa[...]

103 SPECIFICA TIONS Jetting Chart Clutching Ch art Scrambler 500 2X4 Driving System T ype PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (F/N/R) Gear Reduction, Reverse 3 .05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 12/36 76P Drive Chain 520 O-Ring T ires/Pressure, Front 23 x 7-10 (4 psi/27.6 kPa) T ires/Pressure, Rear 22 x[...]

104 POLARIS PRODUCTS P art # Description Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthet ic 2W-50 4-Cycle Oil (gal./3.8 l) Gearcase / T r ansmission Lubricants 2873602 Premium AGL Sy nthetic Gear case Lubricant (q t./.95 l) 2873603 Pre[...]

105 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Starting out going up a steep in cline Use low range (if equipped) or turn around using the K- turn (see page 42). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range (if equipped) more frequently . Insufficient warm-up at low ambie nt tempera- tures[...]

106 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breake r Reset the breaker Low battery voltage Rechar ge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten [...]

107 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommende d fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Possible Cause Soluti[...]

108 TROUBLESHOOTING Engine S top s or Loses Power Possible Cause Solution Out of fuel T urn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Overuse of chok e Inspect , clea n and/or replace spark p lugs Fouled or defective spark plug(s) Insp ect, clean and/o r replac[...]

109 W ARRANTY LIMITED W ARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED W ARRANTY on all components of the Polaris Quadricycle ag ainst defects in material or workma nshi p. This warranty covers the parts and labor char ges for repair or replacement of defective parts which are cove r ed by this warranty[...]

110 W A RRANTY LIMIT A T IONS OF W ARRANTIES AND REMEDIES ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE TWO YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRES S W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . So[...]

111 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COM MENTS[...]

112 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMM ENTS[...]

11 3 INDEX A Air Filt er . . . . . . . . . . . . . . . . . . . . . . 80 B Battery . . . . . . . . . . . . . . . . . . . . 89-94 Charging (Conventional) . . . . . 93 Charging (Sealed) . . . . . . . . 93-94 Fluid (Conventional) . . . . . . . . . 92 Installat ion . . . . . . . . . . . . . . . . 91 Removal . . . . . . . . . . . . . . . . . . 90 Storage[...]

11 4 INDEX I Idle RPM Adjus tment . . . . . . . . . . . 69 Immersion . . . . . . . . . . . . . . . . . . . . 84 Indicator L ights . . . . . . . . . . . . . . . . 23 J Jetting Chart . . . . . . . . . . . . . . . . . . 103 K Key Switch. . . . . . . . . . . . . . . . . . . . 22 K-Turn . . . . . . . . . . . . . . . . . . . . . . . 42 L Lights . . . . .[...]

11 5 INDEX T Throttle Cable Freeplay . . . . . . . . . . 67 Throttle Lever . . . . . . . . . . . . . . . . . . 24 Tires . . . . . . . . . . . . . . . . . . . . . . 77-79 Tread Depth . . . . . . . . . . . . . . . 77 Wheel and Hub Tightening . . . . 77 Wheel Install ation . . . . . . . . . . . 78 Wheel Nu t Torque . . . . . . . . . . 79 Wheel Rem ova[...]