Polaris SCRAER 500 manual

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A car d cont aining import ant A TV saf ety infor mat ion should be at tac hed to t he owner ’s manual on t he next page. If you c annot loc ate t his c ard, or if it has been rem oved, pleas e call 1-800- 342-3764 f or ass ist ance. The engine exhaust from this product contains chemic als know n to cause cancer , birth defects or other reproduct[...]

1 WELC O ME Thank you f or purc ha sing a Polar is vehicle , and welc ome to our wor ld-wide f amily of Polaris owne rs. W e proudly produc e an exc iting line of utility an d re cr ea tiona l produc ts. S Snowmobiles S All- ter ra in vehic le s (A TVs) S RANGER utility vehicle s S V ict ory m ot orcy cles W e belie ve Pola ris sets a standa rd of [...]

2 Copyr ight 2006 Pol a ri s Sa l e s Inc . All inf or ma t i on c ont a i ne d wi t hi n t hi s publi c a t ion i s ba s e d on the l a t e s t pr oduc t i nf or ma t i on a t the t i me of publ i c a t i on. Due t o c ons t a nt imp ro v emen ts in th e desig n an d q uality o f pr oduct i on compone nt s , s ome m i nor d iscrepan cies may resu [...]

3 TABLE OF CONTE NTS VEHICLE IDENT IFI CA TION NUMBERS 5 ....... SA FE TY 6 ................................... FEA TURES AND CONTROL S 31 ............... OPE RA TION 43 .............................. EMI SSION CONT ROL SYST EM S 61 ............ MAINT ENANCE 62 ........................... SPECIF IC A TIO NS 1 10 ........................ POLARIS PRO[...]

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5 VE HICLE IDENTIFICATION NUMBERS Recor d your A TV’ s identifica tion number s and ke y number in the sp aces pro vi ded. Rem ov e th e spare k ey and st ore i t i n a s afe pl ace. An ignition key c an be duplic ate d only by orde ring a Polar is key bla nk (using your key numbe r) a nd mating it with one of your existing ke ys. The ignition sw[...]

6 SA FETY Operator S afety W ARNING Failur e to f ollow t he warnings c ontained in t his m anual can r esult in serious injur y or death. A Polaris A T V is not a t oy and can be hazardous to oper ate. T his vehicle handles different ly t han ot her vehic les, such as motorcycles and cars. A collision o r rollover can occur quickly , even during r[...]

7 SA FETY Operator S afety The f ollowing signal wor ds and symbols appe ar throughout this manua l and on your A TV . Y our safe ty is involved whe n t hese words and symbols ar e used. Beco me fa miliar w ith their mea nings befor e re ading the manua l. The safet y alert s ymbol , on your vehicle or in this manual, alert s you t o the pot ent ia[...]

8 SA FETY Operator S afety W ARNING Serious injury or deat h can res ult if you do not f ollow thes e inst ruct ions and pr ocedures , whic h are out lined in fur ther detail within your owner ’ s manual. S Rea d this manua l and a ll labels c ar ef ully , a nd follow the oper ating proce dures desc ribed. S Neve r oper ate a n A TV without prope[...]

9 SA FETY Operator S afety S Alway s have t he A TV i nsp ected b y an aut hori zed P ol aris d ealer if it ’ s been i nvolved i n an accident. S Ne ver ope ra te on hills too ste ep fo r the A TV or for your a bilities. Pra c tice on sma ller hills be for e attempting lar ger hills. S Alwa ys follow prope r pro ce dure s for climbing hills. Chec[...]

10 SA FETY Operator S afety S W et br ake s may ha ve re duced stopping a bility . T est your br ake s af ter lea ving wa ter . I f ne ce ssary , apply them lightly seve ral times to a llow frict io n to d ry out t he pad s. S Always che ck for obsta cles or people be hind the A TV before ope rat- in g in rev erse. When i t’ s s afe to proceed i [...]

11 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A TV wit hout pr oper inst ruct ion. WHA T C AN HAPPEN The r isk of an acc ident is great ly incr eased if the oper ator does not k now how to oper ate t he A T V proper ly in differ ent s ituat ions and on different t ypes of t errain. HOW T O A VOID TH E HAZ ARD Beginning an[...]

12 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Carr ying a passenger on an AT V. WHA T C AN HAPPEN Carr ying a passenger great ly reduces t he operat or ’s ability to balance and cont rol t he A TV , which could caus e an accident and injury to t he operat or and/or pas senger . HOW T O A VOID TH E HAZ ARD Never c arry a passenger . T he[...]

13 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A TV on public st reet s, r oads or highways. WHA T C AN HAPPEN The A T V c ould collide with anot her v ehicle. HOW T O A VOID TH E HAZ ARD Never oper ate t he A T V on any public st reet , road or highway , including dirt and gr avel roads . I n many st ates it’s illegal t[...]

14 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V af ter consum ing alcohol or dr ugs. WHA T C AN HAPPEN Consumpt ion of alcohol and/ or drugs could ser iously aff ect operat or judgment . Reac tion t ime m ay be slower and operat or balance and per cept ion could be affec ted. Consuming alc ohol and/or drugs bef ore or [...]

15 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD At tem pting wheelies , jum ps and other st unts . WHA T C AN HAPPEN At tem pting s tunt s inc reases the c hance of an accident , including an over tur n. HOW T O A VOID TH E HAZ ARD Never at tem pt wheelies, jumps, or ot her st unts . Avoid exhibit ion driving. W ARNING POTENTI AL HAZ ARD Fa[...]

16 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Removi ng hands from t he handlebars or f eet fr om the f ootr est s during oper ation. WHA T C AN HAPPEN Removing ev en one hand or f oot c an reduce abilit y t o cont rol t he vehicle or could caus e loss of balance and ejec tion f rom the A T V . If t he operator ’ s foot is not fir mly p[...]

17 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Failu re to use extra caut ion when operat ing on exces sively r ough, slippery or loos e terr ain. WHA T C AN HAPPEN Opera ting on e xcessi vely rough, s lippery or loose ter rain could c ause loss of tr act ion or loss of cont rol, which could r esult in an accident or over tur n. HOW T O A [...]

18 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating on ex cess ively s teep hills . WHA T C AN HAPPEN The v ehicle may over tur n. HOW T O A VOID TH E HAZ ARD Never operat e on hills too st eep for t he A T V or for y our abilities . Never oper ate t he A T V on hills s teeper than 25 _ . Prac tic e on smaller hills bef ore at tem pt[...]

19 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD T r aveling downhill impr operly . WHA T C AN HAPPEN Im proper ly desc ending a hill could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Always follow pr oper procedur es for t rav eling down hills as described in the owner ’ s manual. NO T E: A spec ial tec hnique is req[...]

20 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im proper ly cros sing hills and tur ning on hills. WHA T C AN HAPPEN Im proper ly cr ossing or tur ning as hills c ould cause loss of c ontr ol or overt urn. HOW T O A VOID TH E HAZ ARD N e v e ra t t e m p t t ot u r nt h e A TV around on any hill until you’ve m ast ered t he tur ning tec [...]

21 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD St alling, r olling backwar ds or impr operly dism ounting while climbing a hill. WHA T C AN HAPPEN The v ehicle could ov ert urn. HOW T O A VOID TH E HAZ ARD Maint ain st eady speed when climbing a hill. If all f orwar d speed is lost: Keep your weight uphill. Apply t he single lev er brak e [...]

22 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im proper ly operat ing over obstac les. WHA T C AN HAPPEN Oper ating ov er obst acles could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Bef ore operat ing in a new ar ea, chec k f or obst acles . Avoid operating ov er large obs tac les suc h as roc ks and f allen tr ees [...]

23 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T C AN HAPPEN T ir es may f loat, caus ing loss of t ract ion and loss of cont rol, whic h could lead t o an accident or ov ert urn. HOW T O A VOID TH E HAZ ARD Avoid operating t he A T V t hrough deep or f ast -f lowing wat e[...]

24 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V wit h improper modif icat ions. WHA T C AN HAPPEN Im proper ins tallat ion of acces sories or modif icat ion of the A T V may c ause changes in handling which could lead t o an acc ident. HOW T O A VOID TH E HAZ ARD Never modif y t he A T V t hrough improper ins tallat io[...]

25 SA FETY Operator S afety W ARNING Leaving t he keys in the ignit ion can lead t o unaut horized us e of the v ehicle res ulting in s erious injur y or death. Alway s rem ove the ignit ion key when the v ehicle is not in use. W ARNING Af ter any over tur n or acc ident, have a qualif ied ser vice dealer inspect t he entir e vehicle f or pos sible[...]

26 SA FETY Fuel Safety W ARNING Gas oline is highly f lamm able and explosiv e under cer tain condit ions. S Always exerc ise ext rem e caut ion whenever handling gas oline. S Always ref uel with t he engine st opped, and outdoor s or in a well vent ilated ar ea. S Do not smok e or allow open f lames or spar ks in or near the area wher e ref ueling[...]

1 2 27 SA FETY Safety D ecals and Locations W arning d ecals have been pl aced on the A TV for your protecti on. R ead and fol low th e ins t ructi on s o f th e decals on th e A TV carefull y . If an y of the decals depi cted in t his manual differ from the decals on your A T V , alway s read and fo ll ow t he i ns tru cti ons of t he d ecals on t[...]

4 3 28 SA FETY Safety D ecals and Locations Rever se Overr id e W arning (3) W ARNING Pushing r everse over r ide but ton may cause sudden i ncreases i n power and tr acti on if t oo much t hr ot tl e is appli ed. Loss of cont rol or f orwar d fl ipover may resul t, especi all y i n A WD. See Owner’ s Manual . Gene r al W arni ng (4) W ARNING Im [...]

5 7 6 29 SA FETY Safety D ecals and Locations No P assenger W arning (5) W ARNING NEVER r ide as a passenger . Passenger s can cause a los s o f co n trol, re su ltin g in SEVERE INJUR Y or DEA TH. A g e1 6W a r n i n g( 6 ) W ARNING Oper at ing thi s A TV if you are under t he age of 16 incr eases your chance of severe inj ury or death. NEVER oper[...]

30 SA FETY Safe Riding G ear Always we ar c l othing suited to the t ype of r iding. A TV riding requir es spec ial prote ctive c lothing for comf ort and to reduc e the cha nce of injury . 1. Helm et W eari ng a h elm et can p reven t a s evere h ead injury . Whe neve r riding a Polaris vehic le, alway s wear a hel m et t hat m eet s or ex ceeds e[...]

31 FEATURE S AND CONTRO LS Electr ical S witches W ARNING Act ivat ing t he overr ide swit ch while t he thr ott le is open c an cause loss of cont rol, r esulting in s evere injur y or deat h. Do not ac tiv ate the ov erride s witc h while the t hrot t le is open. Ov errid e S wi tch (1 ) (Re ve rse Spe e d Limiter ) - This vehic le is equipped wi[...]

32 FEATURE S AND CONTRO LS Light S witches W ARNING Oper ating t he A T V on st reet s or r oads, especially in darknes s, could res ult in an ac cident and s erious injur y or deat h. Y our A T V is not equipped wit h highway-appr oved light s. I t’s designed f or and mus t be us ed for of f -road use only . Use cau tion and drive at r educed sp[...]

33 FEATURE S AND CONTRO LS Throttle Lever W ARNING Do not s tar t or operat e an A TV with s tic king or im properly operat ing thr ott le cont rols , whic h could caus e an accident and lead to s evere injur y or deat h. Always c ontac t your dealer f or ser vice repair s if t hrot tle problem s arise. Failur e to c heck or maint ain proper oper a[...]

34 FEATURE S AND CONTRO LS Br ake Lever W ARNING Oper ating t he A T V wit h a spongy br ake lever c an result in loss of braking, which c ould cause an ac cident . Nev er operat e t he A TV with a s pongy-f eeling brak e lever . The fro nt and rear b rakes are app li ed by s queezi ng t he brak e leve r (1) towa rd the handle bar . The fro nt and [...]

35 FEATURE S AND CONTRO LS Br akes Ch eck th e brake flu id l evel i n th e mas ter cy li nd er befo re each u se of the A TV . The maste r cy linder ( 1) is lo cated o n th e left h andl ebar . The f luid leve l ca n be se en thr ough an indica tor window (2) on the top of the maste r c ylinder . This “eye ” will appe ar dar k when the f luid [...]

36 FEATURE S AND CONTRO LS Park ing B rak e W ARNING Oper ating t he A T V while t he parking br ake is engaged c ould result in an accident and ser ious injury or deat h. Always c heck t o be sure t he park ing brake is disengaged bef ore oper ating. Setting the P ar king Brake 1. S queeze an d rel ease t he b rake l ever t wo o r thre e times, th[...]

37 FEATURE S AND CONTRO LS Auxiliary Brake W ARNING Aggres sively applying t he rear br ake when back ing downhill may cause r ear t ipover , which c ould result in ser ious injury or death. Use caut ion when applying t he auxiliar y brak e. Do not aggress ively apply the aux iliary br ake when going f orward. T he rear wheels may s kid and slide s[...]

38 FEATURE S AND CONTRO LS Choke The choke a ssists in starting a c old engine. Ref er to the engine sta rting proc edur e on page 45 for corr ec t choke and throttle settings during star ting. Fuel V alve The fu el v alv e (1) i s l ocat ed on th e left si de o f the vehic le, below the fe nder . It has three positions: OFF: For vehic le stora ge [...]

39 FEATURE S AND CONTRO LS Autom atic T r ansm ission Gear Selector The tra nsmission gear se lector (1) is locate d on the right side of the vehic le. F: For war d N: Neutral R: Rev e rs e CAUTION Shif ting gear s wit h the engine s peed above idle or while t he vehicle is moving c ould cause t rans miss ion damage. T o change gear s, s top t he v[...]

40 FEATURE S AND CONTRO LS Recoil S tarter If the ba tter y has be en dr aine d or dama ged a nd ca nnot start the engine , use of the re coil star ter ( 1) will allow ve hicle ope ration until re pair s can be made . The re coil star ter is locate d on the right side of th e mach in e. Polaris 4- cyc le engine s ar e equippe d with a utoma tic dec[...]

41 FEATURE S AND CONTRO LS All W heel Dr ive (A W D) S ystem Po lari s 4-wheel d rive A TVs are equippe d with a unique, Polaris exc l usive , A WD system tha t’ s ac tivate d by a sw itch ( 1) on the r ight handle bar . When the switch is of f, the A TV is in 2 whee l drive at all times. Wh en the switc h is on, the A T V is i n A WD and th e A [...]

42 FEATURE S AND CONTRO LS All W heel Dr ive (A W D) S ystem Di sengagi ng Whee l Hubs Although the hubs norma lly disengage whe n oper ating in re verse, one or both hubs may o ccasional ly rem ain engaged. If the h andlebars pull to one side , it’ s likely that one f ront hub is enga ged . If both hubs are engag ed, s teeri ng effort in creases[...]

43 OPERATION Br eak - In Per iod The br ea k-in per iod for your new Polaris A TV is t he f irst ten hours of oper ation, or the time it takes to use the first two full tanks of gasoline. No single a ction on your par t is as importa nt as following the proc edur es for a pr oper bre ak-in. C ar ef ul treatme nt of a new engine and dr ive compone n[...]

44 OPERATION Pr e -Ride Inspection W ARNING If a proper inspect ion is not done bef ore each us e, s evere injur y or deat h could res ult. A lways ins pect t he vehic le befor e each use to ens ure it ’ s in proper operat ing condit ion. Pre - Ride Che ck li st Item Remarks See Page Br ake system / lever t ravel Ensure proper oper ati on 34, 76 [...]

45 OPERATION Star ting the Engine W ARNING Engine exhaus t c ontains pois onous car bon monoxide and c an cause los s of c onscious ness r esult ing in sever e injury or deat h. Never r un an engine in an enclosed ar ea. 1. Position the vehicle on a leve l su rface. 2. Place the tr ansmission in neutr al. 3. Lock the parking br ake . NOT E: T he st[...]

46 OPERATION Star ting the Engine 7. Move the engine stop switch to R UN. NOT E: Do not pres s t he thr ott le while st art ing t he engine. 8. T urn the ignition ke y past the O N position to enga ge the star ter . Activa te the starte r for a maximum of five se conds, rele asing the key whe n the engine starts. 9. If the engine doe s not start, r[...]

47 OPERATION Driving Safely Driving Pr o cedures 1. Sit upright with both feet on the footre sts and both hands on the handle bar s. 2. Start the e ngine a nd allow it to warm up, then shift the tra nsmission into ge ar . 3. Check your surr oundings and dete rmine your pa th of trave l. 4. Relea se the par king brake . 5. Slowly depre ss t he thr o[...]

48 OPERATION Driving Safely Hauling Cargo Acc essor y ra cks and hitc hes a re ava ilable fr om your Polaris de ale r . Always re ad and under stand the load distr ibution war nings on all warni ng l abel s, and n ever exceed t he sp ecifi ed weig ht cap ac ities for the vehic le. Maxim um T owin g Cap acities Refe r t o the spec ifica tions at the[...]

49 OPERATION Driving Safely Hauling Cargo W ARNING Hauling cargo im proper ly can alt er v ehicle handling and may cause los s of cont rol or br ake inst abilit y and res ult in s erious injury or deat h. A lways f ollow these prec autions when hauling cargo: S REDUCE SPEED AN D ALLO W G REA T ER DI ST ANCE F OR BRAKING WHEN HAULING C ARGO. S CARG [...]

50 OPERATION Driving Safely Making T urns Y our Polar is A TV is equippe d with a solid re ar axle , which dr ives both re ar whe els equa lly at a l l time s. This mea ns tha t the w hee l on the outside of the turn must trave l a grea ter distanc e than the inside wheel whe n turn ing and the inside tire must slip tra ction slightly . T o make a [...]

51 OPERATION Driving Safely Dr iving on Slippe r y Sur faces Whenev er ridi ng o n sl ip pery su rfaces su ch as wet trai l s or lo ose grav el, or du ring freezi ng weat her , fol l ow th ese precaut i ons : 1. Slow down when e nter ing slippery a re as. 2. Mai nt ain a h ig h l evel o f al ert ness , read in g t he t rai l and avo id in g qui ck,[...]

52 OPERATION Driving Safely Sidehilling W ARNING Im proper ly cr ossing hills or t urning on hills c an result in loss of cont rol or v ehicle over tur n, r esult ing in sever e injury or deat h. Avoid cross ing the s ide of a hill when pos sible. F ollow proper procedur es as out lined in t he owner ’s manual. Sidehilling ca n be a dange rous ty[...]

53 OPERATION Driving Safely Driving Uphill W ARNING Brak ing and handling are gr eatly aff ect ed when operat ing in hilly ter rain. I mproper proc edure could c ause loss of cont rol or overt urn and r esult in ser ious injury or deat h. Avoid climbing st eep hills ( 25 _ maximu m). Use ext rem e caut ion when operat ing on hills, and f ollow pr o[...]

54 OPERATION Driving Safely Driving Uphill Whe never tr av eling uphill, follow these pr ecaut io ns : 1. Alwa ys tra vel stra ight uphill. 2. A void stee p hills (25 _ ma ximum). 3. Kee p both fe et on the f ootre sts. 4. T ransfe r your weight forwa rd. 5. P roceed at a st eady rat e of sp eed and t hro ttle ope ning. 6. Rema in ale rt and be pre[...]

55 OPERATION Driving Safely Driving Downh ill Whe ne ver de sce nding a hill, follow these pr ecauti on s: 1. P roceed di rect ly d own h ill. 2. T ransf er your we ight to the re ar of the ve hic le. 3. Sl ow down. 4. Apply the brakes slightly to aid in slowing, using the single br ake leve r . NOT E: F amiliar ize your self wit h operat ion of th[...]

8’ (2. 4 m) 56 OPERATION Driving Safely T urning A round on a H il l If the ve hic le stalls while c limbing a hill, never b ac k it down the hill! Use the K- turn to turn a round. 1. Stop and lock the pa rking brake while kee ping body we ight uphill. 2. Lea ve the tra nsmission in forw ar d and shut of f the e ngine. 3. Dismount on the uphill s[...]

57 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV can ope ra te thr ough wate r with a maximum re co mmende d depth e qual to the bottom of the footr ests (1) . F ollow th ese pro cedu res when oper ating through wa ter : 1. De ter mine wa ter depths a nd cur rent bef ore c rossing. 2. Choose a crossing wher e both banks have gra dual[...]

58 OPERATION Driving Safely Dr iving Over Obstacles Be al ert! L ook ah ead and l earn to read t he terrai n yo u’re trav eli ng on . Be con st ant l y alert fo r hazards s uch as l og s, ro cks an d lo w hangi ng bran ches . W ARNING Sever e injury or deat h can r esult if your v ehicle com es in cont act with a hidden obs tac le. Not all obst a[...]

59 OPERATION Driving Safely Dr iving in Reverse F ol lo w th ese p recaut io ns when op erati ng i n revers e: 1. Always avoid ba cking downhill. 2. Bac k slowly . 3. When i n reverse, apply the brake s lightly for stopping. 4. A void turning at shar p angle s in re ver se. 5. Ne ver ope n the throttle suddenly while ba cking. W ARNING Failur e to [...]

60 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void par king on an inc line if possible . If it’ s unavoidable , follow th ese p recaut io ns : 1. T urn the engine of f. 1. Place the tr ansmission in gear . 2. Set t he par king brake . 3. Always block the rea r wheels on t he downhill side. S ee illustra tion. 4. Shut of f the fue[...]

61 EMISSION C ON TR OL SYST EMS Noise E mi ssion Contr ol System Do not modify the engine, intake o r exhaust compone nts, as doing so may af fect complia nce with U. S.A. EP A noise contr ol require ments (40 CFR 205) and loc al noise leve l require ments. Operation on Public Lan ds in the U.S.A. Y our Pola ris ve hicle ha s a spa rk a rr estor th[...]

62 MAINTENANCE Per iodic Maintenance C hart Care ful per iodic mainte nanc e will help keep your vehic le in the safe st, most relia ble condition. Inspe ction, adjustme nt and lubric ation of importa nt components ar e expla ined in the periodic mainte nanc e char t. Ins pect , clean , lu bri cate, ad jus t and repl ace parts as necess ary . When [...]

63 MAINTENANCE Per iodic Maintenance C hart Maintena nce C har t Key " P erform t hes e pro cedures m ore freq uent l y for v ehi cles s ubj ect ed t o seve re use . E Emission-r ela ted se rvic e (Failur e to conduc t t his mainten anc e will not void the emissions warra nt y but may af fe ct e missions.) J Have an au th orized P ol aris d ea[...]

64 MAINTENANCE Per iodic Maintenance C hart Item Maint enance Int erval (w hichev er c omes fir st ) Remarks Hours C alendar Miles (Km) " J Brak e pad w ear 10 H Monthly 100 (160) Ins pec t periodic ally Battery 20 H Monthly 200 (320) Chec k ter minals; c lean; tes t " Front gear c ase oil 25 H Monthly 250 ( 400) Inspec t lev el; c hange [...]

65 MAINTENANCE Per iodic Maintenance C hart Item Maint enance Int erval (w hichev er c omes fir st ) Remarks Hours C alendar Miles (Km) " Cooling hos es (if applic able) 100 H 12 M 1000 (1600) Ins pec t for leak s " Engine mounts 100 H 12 M 1000 ( 1600) Inspec t Ex haus t muf fler/ pipe 100 H 12 M 1000 (1600) Ins pec t J E Spark plug 100 [...]

66 MAINTENANCE Lubr ication Recom m endations Chec k a nd lubric ate all c omponents a t the inter va ls outlined in the Periodic Ma intena nce Cha rt beginning on page 62. Items not listed in the cha rt should be lubrica ted at the Gene ral Lubrica tion interva l. NOT E: T he a-ar ms and lower cont rol ar ms ar e lubricat ed at t he fac tor y , an[...]

67 MAINTENANCE Lubr ication Recom m endations (1) (3) (2) (7) (6) (4) (5) 4 or 8 o’cl ock posit ion- ( end view) (8)[...]

68 MAINTENANCE Engi ne Oil Alwa ys chec k and cha nge the engine oil at the interva ls outlined in the P eriod ic M ai nten ance C hart beg i nning on page 62. Always change the oil filter whe never c hanging oil. Pr em ium 4 Synthetic Oil Polaris Pre mium 4 All Season Synthetic engine oil has be en spe cia lly for mulate d fo r use in Polar i s 4-[...]

69 MAINTENANCE Engi ne Oil Oil an d Filter Chang e CAUTION Contac t with hot oil may result in serious burns . Do not allow hot oil to c ome int o cont act wit h sk in. 1. Position the vehicle on a leve l surf ace. C l ean t he are a around the dra in plug at the bottom of the oil tank and the bottom of the engine . 2. Run the engine for two to thr[...]

70 MAINTENANCE Engi ne Oil Oil an d Filter Chang e 9. Plac e shop towels be nea t h the oil f ilter . Using an oil f ilter wre nch, turn the filte r (1) c ounter clockw ise and re move. 10. Lubric ate the gaske t on the new filte r with a film of new engine oil. Check to ma ke sur e the gaske t is in good condition. Also make sur e the gaske t from[...]

71 MAINTENANCE Engi ne Oil Oil an d Filter Chang e Oil Pump Pr iming This priming proc edur e must be perform ed wh enever t he o il h os e conne c tion betwe en the oil ta nk and pump inle t has bee n disconne cte d. 1. Clamp or pinch of f the vent line (1) a pproxima tely 2 I fro m the oil tank (2), betw ee n the end of the oil tank ve nt fitting[...]

72 MAINTENANCE T r ansmission Oil Alwa ys chec k and cha nge the transmission oil at the interva ls outlined in the Periodic Mainte na nce Cha rt beginning on page 62. Maintain the oil level at the bottom of the fill hole threa ds. W e rec ommend the use of Premium AGL S ynthetic Ge ar ca se Lubric ant. See page 1 13 for the par t numbers of Polari[...]

73 MAINTENANCE Front Gear case Oil Oil Check Alway s ch eck and ch ange t he fro nt g earcase oi l at t he in terv als outlined in the Periodic Ma intena nce Cha rt beginning on page 62. Mainta in the oil leve l at the bottom of the f ill plug thre ads. W e re comme nd the use of P olar is A TV Angle Drive Fl uid. See page 1 13 for the pa rt number[...]

74 MAINTENANCE Drive Chain Polaris A TV drive c hains ar e equippe d with o-ring-se ale d, perma nently greas ed pi ns and r ol lers . H owev er , t he ou ter s urfaces o f th e rol ler m us t be lubric ate d. Always inspe ct the dr ive c hain prior to ope rating the ve hicle. Chec k for dama ged or missing o-r ings or dama ged roller s. Also che c[...]

75 MAINTENANCE T oe A lignm ent W ARNING Sever e injury or death c an result f rom im proper t oe alignment and adjust ment . Do not at tem pt t o adjust t ie rod alignment . All t ie rod adjust ment s should be per for med by an aut horiz ed Polaris dealer . Use the following proce dure to che ck the toe alignme nt of the vehicle . The re comme nd[...]

76 MAINTENANCE Br akes The front and re ar br ake s are hydra ulic disc brakes, activa t ed by moving the single brake le ver towar d the handleba r . These bra kes are self -a djusting. The fo ll owi ng ch ecks are reco mm ended t o k eep t he brak e sy st em i n good oper ating c ondition. Check mor e of ten if bra kes a re used he avily under no[...]

77 MAINTENANCE Br akes 1. Ch eck t he b rake sy st em fo r flu id leak s. 2. Ch eck t he b rakes fo r exces si ve t ravel or spongy fe el. 3. Ch eck th e fricti on p ads fo r wear , dama ge and loosen ess. 4. Ch eck th e securi ty an d su rface condition of the disc. NOT E: P ads should be c hanged when worn t o 3/64 ″ (. 1 cm). Auxiliary Brake T[...]

78 MAINTENANCE Steer ing Assem bly The ste er ing asse mbly of the A TV should be c hecke d per iodica lly for loose nuts and bolts. If loose nuts and bolts are f ound, see your Polaris dea ler for se rvic e bef ore ope rating the vehic le. Cam ber and C aster The ca mber a nd caste r ar e non-a djustab le. Rear S pri ng The re ar shoc k absorbe r [...]

79 MAINTENANCE Handlebar s W ARNING Im proper adjust ment of t he handlebars or incor rec t tor quing of the adjus ter bloc k t ightening bolt s c an cause lim ited s teer ing or loosening of the handlebar s, result ing in loss of c ontr ol and possible s erious per sonal injury or deat h. F ollow t he adjust ment procedur es exact ly , or s ee you[...]

80 MAINTENANCE Car bur etor IMPOR T ANT : Y our Polar is A TV is ca libra ted at the f ac tory f or optimal pe rf orma nce at altitude s ranging fr om ze ro to 6,000 fe et ( 1800 m) and temper atur es of +40 degre es F . (4 degr ee s C. ) or higher . Above 6000 fe et (1800 m) the e ngine a ir/fu el mixture bec ome s overly r ich a nd the engine los[...]

81 MAINTENANCE Wheels W ARNING Oper ating y our A T V wit h worn t ires, impr operly inf lat ed tir es, non-st andard t ires or impr operly ins talled tir es will affect v ehicle handling and could caus e an accident res ulting in s erious injur y or death. Maint ain proper t ire pr essur e as desc ribed on t he decal on your A TV and in your owner[...]

82 MAINTENANCE Wheels Wheel Installation 1. Place the tra nsmission in gear a nd lock the par king bra ke. W ARNING Im proper ly installed wheels can adver sely affec t t ire wear and vehicle handling, which c an result in ser ious injur y or deat h. Always ensure t hat all nuts are t orqued t o specif icat ion. Do not serv ice axle nut s t hat hav[...]

83 MAINTENANCE Wheels Fr ont Whee l Hub T ightening Front whee l bea ring tightne ss and spindle nut rete ntion ar e c ritic al compone nt oper ations. All se rvic e must be per for med by your aut ho rized P ol ari s deal er . Ti re T read Depth Alway s repl ace tires wh en tread depth is wor n to 1/8 ″ (.3 cm) or le ss. See illustr a tion. W AR[...]

84 MAINTENANCE Rear Dr ive Chain Sl ack CAUTION Adjust ing or oper ating t he A T V wit h improper r ear dr ive chain slack can res ult in s evere dam age to t he t ransm ission and dr ive component s. Alway s mak e sure t he slac k is wit hin t he st ated specif icat ions. Chec k the a mount of cha i n slac k in three d if fere nt locations by mov[...]

85 MAINTENANCE Rear Dr ive Chain Sl ack 6. R ol l t he A TV forward o r back ward to adjust the cha in sla ck to the prope r tension. See the illustra tion for pr oper splic e link clip opening position (1) . 7. T i ght en t he eccen tri c l ocki ng bo lt s to 30 ft. lbs. (41 Nm) for ma chines without the hitc h and 45 ft. lbs. (61 Nm) for ma chine[...]

86 MAINTENANCE Engi ne Cooli ng System Coolant Level The re covery bottle (1 ) is loca ted on the left side of the machine . The fluid leve l must be maintained betw ee n the minimum and maximum mar ks on the bottle (whe n the f luid is cool). The engine c oolant leve l is contr olled or mainta ined by the re cove ry system. The rec over y system c[...]

87 MAINTENANCE Engi ne Cooli ng System W ARNING Esc aping st eam can c ause sev ere burns . Nev er rem ove t he press ure cap while t he engine is war m or hot . A lways allow t he engine to c ool befor e remov ing the pr essur e cap. Radiator Coolant Level NOT E: T his proc edure is requir ed only if the c ooling system has been drained f or maint[...]

88 MAINTENANCE Lights Whe n ser vic ing a ha logen la mp, don’t touc h the lamp with ba re finger s. Oil from your skin le ave s a residue , ca using a hot spot that will shorten the life o f the lamp. W ARNING Poor light ing while driv ing can res ult in s evere injur y or deat h. Headlight and t aillight lenses bec ome dir ty dur ing normal ope[...]

89 MAINTENANCE Lights T aillight/Brakelight La m p Replacement If the taillight/br ake light does not wor k the la mp may nee d to be repl aced. 1. Remove the ta illight lens cover mounting scre ws. Remove the lens c over a nd gasket and se t aside f or re asse mbly . 2. Remove the lamp (1). 3. Apply dielec tric gre ase to the so cket and i ns tal [...]

90 MAINTENANCE Filter System s Air Filter Service 1. Rem ov e th e seat , rel ease the clips, and remove the air box cover . 2. Loosen the cla mp and r emove the filte r . 3. Remove the f abr ic type pre -filte r (1) fr om the ma in filte r ( 2). W ash the pre -f ilter in soapy wa ter , then rinse and l et dry . 4. Reinsta l l the pre- filte r over[...]

91 MAINTENANCE Spar k P lugs S par k P lug Re com mendati ons CAUTION Using non-r ecom mended spar k plugs c an result in ser ious engine damage. Alway s use P olaris- recom mended spar k plugs. Ref er to t he spec ific ations s ect ion beginning on page 1 10 . Refe r to the spe cif ications se ction be ginning on page 1 10 for the re comme nded sp[...]

92 MAINTENANCE Spar k P lugs Spar k Plug Inspectio n Normal Plug The norma l i nsulator tip is gray , tan or light brown. There w ill be few combustion deposits. The ele ctrode s are not burned or er oded. This indica tes the proper type a nd heat range f or the engine a nd the servic e. NOT E: T he t ip should not be whit e. A whit e insulat or t [...]

93 MAINTENANCE V eh icl e Imme rsio n CAUTION If your vehicle bec omes im mer sed, m ajor engine dam age can result if the m achine is not t horoughly ins pect ed. T ak e the vehicle t o your dealer befor e st art ing the engine. If it’ s impossible to take your A TV to a dea ler be for e starting it, follow the steps outlined below . 1. Move the[...]

94 MAINTENANCE PV T System The basic ope ra tion of the P olar is P VT system is depende nt on engine sp eed and v ehi cle t orq ue requ irem ent s. As en gi ne sp eed i ncreas es, th e for ce e xerte d on the m ovable dr ive shea ve by the flyweights also incr ea ses. This, in turn, incre ase s the amount of “ pinc h” a pplied to the drive be [...]

95 MAINTENANCE PV T System W ARNING Failur e to c omply wit h t he inst ruct ions in t his war ning can res ult in sever e injury or death. Do not modify any component of th e PVT syst em. Doing so may reduce it s s tr ength s o that a f ailure may oc cur at a high speed. The PVT syst em has been precisio n balanced. Any m odificat ion will cause t[...]

96 MAINTENANCE Spar k Ar r estor W ARNING Failur e to heed t he f ollowing warnings while s ervic ing the s park arr estor c ould result in ser ious injury or deat h. Do no t perform service o n the spa rk arrestor wh ile the system is hot. Exhaust system t em peratures ca n r each 1000 ° F . Allow component s t o cool s ufficient ly bef ore pr oc[...]

97 MAINTENANCE Batter y Y our A TV may ha ve e ither a se ale d batter y , which re quires little mainte nanc e, or a conve ntional ba tter y . A sea l ed ba ttery c an be identif ied by its f lat c over s on the top of the batte ry . A conve ntional batte ry ha s six filler ca ps on the top of the ba ttery . Conve ntional B atter y Always ke ep ba[...]

98 MAINTENANCE Batter y W ARNING Im proper ly connect ing or disconnect ing batt ery c ables can result in an explosion and c ause ser ious injury or deat h. W hen rem oving the bat t ery , always dis connect t he negativ e (black ) cable f irst . W hen r einstalling t he bat ter y , alway s connec t t he negativ e (black ) cable las t. Batt ery Re[...]

99 MAINTENANCE Batter y Battery Installation Using a ne w ba tter y that has not be en f ully cha rge d can da mage the bat tery an d resu lt i n a sho rter l ife. It can al so h in der veh icl e per forma nce . Follow the batte ry ch ar ging instructions on pa ges 101-103 bef ore insta lling the batte ry . 1. Ensur e that the batte ry is fully cha[...]

100 MAINTENANCE Batter y Batter y Stor age Whe ne ver the ve hicle is not used for a per iod of three months or more, remo ve t he bat tery from t he v ehi cle, ens ure t hat i t ’ s fu ll y ch ar ged, an d st ore it ou t of t he sun i n a cool , d ry pl ace. C heck bat tery v ol tag e each mo nt h du rin g st orag e and recharge as needed t o ma[...]

101 MAINTENANCE Batter y Batte r y Fluid (Conv entional B atter y) A poorly ma intained ba tter y will dete rior ate r ap idly . Chec k the batter y fluid le vel of ten. Mainta in the fluid leve l between the upper a nd lower leve l mar ks (1) . Add only d istilled w ate r . T ap wa ter conta ins minera ls that ar e ha rmf ul to a batte ry . Batter[...]

102 MAINTENANCE Batter y Batter y Charging (S ealed Battery) The f ollowing batte ry c har ging instructions a pply only to the in st all ati on o f a s ealed b att ery . R ead all i nst ruct i ons b efore proceed in g with the installa tion of this batte ry . The sea led batte ry is alr ea dy f illed w ith ele ctrolyte a nd ha s bee n sea led and [...]

103 MAINTENANCE Batter y Batter y Charging (S ealed Battery) NOT E: A lways ver ify bat t ery condit ion befor e and 1- 2 hours aft er t he end of c harging. Stat e of Char ge Vo l t a g e Acti on Charge T i me* (Us ing cons tant cur rent char ger @ standard amps spec ified on top of battery ) 100% 12.8- 13.0 volt s None, check at 3 mos. fr om date[...]

104 MAINTENANCE Cleaning a nd Stor age See page 1 13 for the part number s of P olar is products. W ashin g the V eh icle Kee ping your A TV cle an will not only improve its appe ar anc e but it ca n also e xtend the life of va rious c omponents. CAUTION High water press ure m ay damage A T V c omponent s. Polaris recom mends was hing the v ehicle [...]

105 MAINTENANCE Cleaning a nd Stor age W ashin g the V eh icle If a high pr essur e wa ter syste m is used for c lea ning (not recom men ded ), ex ercis e ext reme cau ti on . T he wat er m ay dam age components and could rem ove pain t and decals. A voi d directin g the wa ter stre am a t the follow ing items: S Wheel b earin gs S Radiator S T ran[...]

106 MAINTENANCE Cleaning a nd Stor age Chr ome W heel Car e (if equi pped) P roper mai nt enance wil l pro tect ch rom e wh eels fro m corros io n, pres erve wheel li fe and ens ure a ”li ke n ew” appearan ce for m any y ears. NOT E: Chr ome wheels ex posed t o road salt (or salt in the air in coast al areas ) are m ore sus cept ible to c orros[...]

107 MAINTENANCE Cleaning a nd Stor age Sto ra ge Ti ps See page 1 13 for the part number s of P olar is products. CAUTION St art ing the engine dur ing the s tor age period will dist urb t he prot ect ive f ilm cr eated by fogging and damage c ould occur . Never st art the engine during t he st orage per iod. Clean t he Exterio r Mak e any necess a[...]

108 MAINTENANCE Cleaning a nd Stor age Sto ra ge Ti ps Flu id L evels Inspe ct the fluid le vels. Add or c hange fluids a s re comme nded in the Periodic Mainte nanc e Char t beginning on page 62. S Dema nd drive unit (f ront gea rcase ) S Rear g earcase (i f equ ip ped ) S T ransmission S Bra ke f luid (c hange e ver y two ye ar s and a ny time th[...]

109 MAINTENANCE Cleaning a nd Stor age Sto ra ge Ti ps Inspe ct a nd Lubric ate Ins pect al l cab les and l ub ri cate al l areas of t he v ehi cle as recom men ded in the P e riodic Mainte na nce Cha rt beginning on page 62. Batte ry S tora ge See pa ges 100- 103 for stor age and c har ging proce dures. Sto rage Ar ea/Co vers Set the tire pre ssur[...]

11 0 SPECIFIC ATIO NS 2007 Scr am bler 500 4X 4 Capac ities Body Styl e Gen III Gro ss V eh icle W eig h t 845 l bs . ( 383 kg) Fue l 3.5 ga l. (13. 2 l) Transm issio n Oi l 32 oz . ( 946 ml ) Coola nt 2.25 qt s. (2. 13 l ) Engi ne Oi l 2 qt s . ( 1.89 l ) F ron t R ack (A ccessory ) 30 l bs . (13. 6 kg) (Ma ximum ) Rear R ack (A ccesso ry) 60 l bs[...]

111 SPECIFIC ATIO NS 2007 Scr am bler 500 4X 4 Drive S ystem Dr i ve Sys t e m T ype PVT Shi ft T ype Side Le ver ( F-N- R) Ge a r Re duc ti on - Reve r se 4. 74/1 Gear R ed u ction - F o rward 3. 06/1 Fro n t D riv e (ratio) 2/ 1 Fi nal D riv e (ratio) 13/36 76P Driv e C hain 520 O- Ri ng Fr ont T i re s 2 3x7 - 1 0( 4p s i ) Rear Tires 22 x 1 1- [...]

11 2 SPECIFIC ATIO NS 2007 Scr am bler 500 4X 4 Jetting Chart Altitu d e AMBIENT TEMPERA TURE Below 40 ° F (B elow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (F eet) 0-1800 (0- 6000) 160 155 1800-3700 (6000- 12000) 152.5 147. 5 Cl utching C hart Altitude Shi ft W eight Dr ive C lutch Sprin g Driven Cl ut ch Sprin g Helix /Spring Setting[...]

11 3 POLARIS PRODUCTS Part No. Descr i pti on Engine Lubr icant 2870791 Fogging O il ( 12 oz. Aerosol ) 2871281 Prem ium 4 Synthet ic 0W -40 ( 4-Cycl e) Engi ne Oil ( qt .) 2871844 Prem ium 4 Synthet ic 0W -40 ( 4-Cycl e) Engi ne Oil ( gal .) Gear case / T ransm i ssion Lubr icant s 2873602 Prem ium AGL Synt heti c Gearcase Lube ( qt .) 2873603 Pre[...]

11 4 TROUB LE SH OOTIN G Contac t your P olar is deale r for se rvice if you’r e unable to identify solutions using the follow ing cha rts. Dr ive Belt and Cover Pr o blems Possibl e Cause Solut ion Dr i vi ng onto a pi c kup or tall trailer in hig h rang e Shi ft t ra nsm is si on to l ow r ange duri ng loa di ng of the A TV t o pre vent be lt b[...]

11 5 TROUB LE SH OOTIN G Engine Doesn’t T urn Over Po ssibl e Cause Sol uti on Trip ped circu it b reak er Reset th e b reak er Lo w b attery v o ltag e Re c ha r ge bat t e ry t o 12.8 VDC Loos e ba t te ry conne ct ions Ch eck all con n ectio n s an d tigh ten Loos e s ole noid conne ct ions Ch eck all con n ectio n s an d tigh ten Engine T urn[...]

11 6 TROUB LE SH OOTIN G Engine Backfir es Po ssibl e Cause Sol uti on W e a k s pa r k fr om s pa rk pl ugs In sp ect, clean an d/o r repl ace spark p lu g s In correct sp ark plu g g ap o r heat rang e Se t ga p to spe cs or r epl a c e plugs Ol d or non-r e c omm e nde d f ue l Re pla ce w it h new fue l In correctly in stalled sp ark p lu g wir[...]

11 7 TROUB LE SH OOTIN G E ngine S tops or Loses Pow er Po ssibl e Cause Sol uti on Out of fuel Tu rn fuel v alve to reserv e, refu el Ki nke d or plugge d fue l vent l i ne Insp ect an d rep lace W ater p resent in fu el Re pla ce w it h new fue l Ove rus e of c hoke In spect, clean an d/ or repl ace spark p lu g s Foul e d or de fe ct ive spa rk [...]

11 8 WARRANTY LIM IT ED W ARRANTY Pol a ri s Sal es I nc . , 2100 Hi ghway 55, M e dina , M N 55340, gi ve s a SI X M ONTH LIM I TED W ARRANTY on al l compone nts of t he Pola ri s Al l T er ra in V ehi cl e ( A TV) aga ins t def e c t s i n ma t e r ia l or wor kma ns hip. Pola r i s a ls o give s a one ye ar l i mi t e d wa rr a nt y on the f ina[...]

11 9 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TIO NS OF W ARRANTIE S AND REMEDI ES ALL IM PLIED W ARRANTIES ( INCLUDI NG BUT NOT LIMI TED T O THE IM PLIED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MI TED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD. POLARI S FUR THER DISCLAI MS ALL EXP[...]

120 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE I S NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THI S VEHICLE I F IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORIZED LOCA- TION. Th is po licy d o es no t app ly to v eh icles th at h ave received au th o rizatio n for e xpor t fr om Pol a r[...]

121 WARRANTY U. S.A. EP A Emi ss io n s L i mit ed W a rran t y Th is A ll T errain V eh icle (A T V) or O ff Ro ad U tility V eh icle (OR UV ) em ission s lim ited warran ty is in add ition to t he Po laris stan dard lim ited warran ty fo r this v ehicle. P olaris w arran ts th at th is veh icle is; (1 ) d esig n ed, bu ilt, an d eq u ip ped to co[...]

122 MAINTENANCE LOG Use t he fol l owi ng ch art t o reco rd peri od ic m ain ten ance. DA TE MIL ES ( KM) TECHNICIAN SER VIC E PERFOR MED / COMMENTS[...]

123 MAINTENANCE LOG DA TE MIL ES ( KM) TECHNICIAN SER VIC E PERFOR MED / COMMENTS[...]

124[...]

125 INDEX A Ag e R estrictio ns 6 ................ Air F ilter 9 0 ..................... Al l Whe el Dr ive 41- 42 ............. Au x iliary B rake 3 7 , 7 7 ............ A WD 41- 42 ...................... B Ba tt er y 97-103 ................... Ba tt er y Char ging ( Conve nt iona l) 101 . Ba tt er y Char ging ( Se a le d) 102-103 .... Ba tt er y [...]

126 INDEX N Noi s e Emi s s i on Cont rol Sys te m 61 ... O Oi l Cha nge 69- 71 ................. Oil F ilter C han g e 7 1 .............. Oi l Pump Pri ming 71 .............. Oi l , Engine 68- 71 ................. Oil, F ro n t Gearcase 7 3 ............. Oil, Tran sm ission 7 2 .............. Ope r a t or Sa fe ty 6-25 ............... Ov errid e S[...]