Polaris Scrambler 500 4x4 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 We’ve cr eated a Web sit e ju st f or you! S T echnical ti ps S New product introductions S Event schedules S Parts and Se rvice M anual information S Exciting details about The W ay Out Ch e c k it ou t... www .polar isindustr ies.com /owner[...]

2 Copyr ight 2003 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 WELC O ME Thank you f or purc hasing a Polar is vehic le, and we lcome to our wor ld-wide f amily of Polaris owne rs. W e proudly produc e an exciting line of utility a nd re cre ational produc ts. Polar is Recr eatio nal and Utility V ehicles S Snowmobiles S All- ter rain ve hicle s (A T Vs) S W at ercraft S V ict ory m ot orcy cles S RANGER uti[...]

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5 TABLE OF CONTE NTS WELCO ME 3 ................................. VEHICL E IDENTI FICA TION NUM BERS 6 ........ SAFET Y 7 ................................... FEA TURES AND CONTROLS 37 ............... OPE RA TION 49 .............................. EMI SSION CONTRO L SYSTEMS 68 ............ MAINTENANCE AND LUBRICA TION 69 ......... SPECIF ICA TIO NS 1[...]

6 VE HICLE IDENTIFICATION NUMBERS The vehic le fra me vehic le identific ation number (VIN) (1) and engine ser ial numbe r a re impor tant f or mode l i dentif ication w hen re gistering your ve hicle, when obta i ning insura nce, and whe n ordering replacem ent part s. If your vehicl e is s tol en, t hese numbers are essenti al to the r ec overy a[...]

7 SA FETY Operator S afety Age Restr ictions This vehi cle is an ADUL T VEHICLE ONL Y . Operati on is prohi bited for anyone under 16 ye ars of age . Know Y our V e hicle As the opera tor of the vehicle , you are re sponsible for your persona l saf ety , the safe ty of others, and the prote ction of our environme nt. Read a nd understand your owner[...]

8 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 saf et y alert s ymbol, on your A T V or in this manual, aler ts you t o the pot ent ial [...]

9 SA FETY Operator S afety S Rea d this manual and a ll l ab els ca ref ully , and f ollow the ope rating proce dures desc ribed. S Neve r oper ate a n A TV without proper instr uction. T ake a training course . B eginners shoul d recei ve training from a certi fied ins tructo r . Co nt act an aut ho rized P ol aris A T V deal er or cal l P ol ari [...]

10 SA FETY Operator S afety S Alway s have t he A TV i ns pected b y an aut hori zed P ol aris d ealer i f it ’ s b een invol ved in an accident . S Ne ver ope rate on hills too steep fo r the A TV or for your a bilities. Pra ctice o n smalle r hills befo re a ttempting lar ger hills. S Alwa ys follow prope r proc edures fo r climbing hills. C he[...]

11 SA FETY Operator S afety S W et bra kes may ha ve re duced stopping a bility . T est your br akes a fte r lea ving wate r . If ne cessa ry , apply the m lightly seve ra l times to allow 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 bef ore oper at- in g in rev erse. When i t’ s s afe to proceed i [...]

12 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV wit hout pr oper inst ruct ion. WHA T CAN H APPEN The r isk of an acc ident is great ly inc reased if t he operat or does not know how t o operat e the A T V pr operly in diff erent sit uations and on different t ypes of t errain. HOW T O A VOID TH E HAZ ARD Beginning and inexper [...]

13 SA FETY Operator S afety POTENTI AL HAZ ARD Carr ying a passenger on an A T V . WHA T CAN H APPEN Carr ying a passenger great ly reduc es the operat or ’s ability t o balance and cont rol t he A T V , which could c ause an accident and injury t o t he operat or and/ or pass enger . HOW T O A VOID TH E HAZ ARD Never c arry a passenger . T he pu[...]

14 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating an A T V on pav ed surf aces , inc luding sidewalks , paths , par king lot s, and driveway s. WHA T CAN H APPEN A TV tir es ar e designed for off- road use. O perat ing on paved surf aces may s eriously affect t he handling and cont rol of the A TV and could result in loss of contr ol, accid[...]

15 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV on public st reet s, roads or highway s. WHA T CAN H APPEN The A T V c ould collide wit h another vehicle. HOW T O A VOID TH E HAZ ARD Never operat e the A T V on any public str eet, road or highway , including dirt and gr avel roads . In many st ates it’s illegal to operat e A [...]

16 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A T V wit hout wearing an approv ed helmet , ey e prot ect ion and prot ect ive clot hing. WHA T CAN H APPEN Oper ating an A T V wit hout an approved helm et inc reases the ris k of a s evere head injur y or deat h in t he event of an accident . Oper ating wit hout eye prot ect ion cou[...]

17 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t he A T V af ter consum ing alcohol or dr ugs. WHA T CAN H APPEN Consumpt ion of alcohol and/ or drugs could ser iously aff ect operat or judgment . React ion ti me may be slower and oper ator balance and perc eption c ould be affect ed. Consuming alc ohol and/or drugs bef ore or while oper[...]

18 SA FETY Operator S afety POTENTI AL HAZ ARD At tem pting wheelies , jum ps and ot her st unt s. WHA T CAN H APPEN At tem pting s tunt s inc reases the c hance of an accident , including an overt urn. HOW T O A VOID TH E HAZ ARD Never att empt wheelies , jumps, or ot her stunt s. Avoid exhibition driving. W ARNING[...]

19 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to ins pect the A T V bef ore oper ating. Failur e to pr operly m aintain t he A T V . WHA T CAN H APPEN Poor m aintenanc e increas es t he possibilit y of an acc ident or equipment dam age. HOW T O A VOID TH E HAZ ARD Always inspect your A TV befor e each use t o mak e sure it ’s in saf e o[...]

20 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to us e ext ra caut ion when operat ing t he A TV on unfam iliar terrai n. WHA T CAN H APPEN Unfamiliar t errain ma y cont ain hidden rocks, bumps, o r holes that could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD T rav el slowly and us e ext ra caut ion when operat ing on[...]

21 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to us e ext ra caut ion when operat ing on exc essiv ely rough, s lippery or loose t err ain. WHA T CAN H APPEN Oper ating on ex cess ively r ough, s lippery or loose t err ain could cause los s of tr act ion or loss of c ontr ol, whic h could res ult in an accident or over tur n. HOW T O A VO[...]

22 SA FETY Operator S afety POTENTI AL HAZ ARD T urning im proper ly . WHA T CAN H APPEN Im proper t urns could caus e loss of cont rol and lead t o a collis ion or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or tur ning as described in the owner ’s manual. Prac tic e tur ning at s low speeds bef ore at t empt ing t[...]

23 SA FETY Operator S afety POTENTI AL HAZ ARD Climbing hills im properly . WHA T CAN H APPEN Im proper hill c limbing could c ause loss of c ontr ol or over tur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or climbing hills as desc ribed in the owner ’ s manual. Always check the t err ain caref ully bef ore as cending any h[...]

24 SA FETY Operator S afety POTENTI AL HAZ ARD T rav eling downhill impr operly . WHA T CAN H APPEN Im proper ly descending a hill c ould cause los s of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or tr aveling down hills as descr ibed in the owner ’ s manual. NO T E: A s pecial t echnique is r equired w[...]

25 SA FETY Operator S afety POTENTI AL HAZ ARD Im properly cros sing hills and t urning on hills . WHA T CAN H APPEN Im proper ly cros sing or turning as hills could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Never at t empt to t urn t he A T V around on any hill until y ou’ve mast ered t he t urning t echnique (on lev el g[...]

26 SA FETY Operator S afety POTENTI AL HAZ ARD St alling, r olling backwar ds or impr operly dis mount ing while climbing a hill. WHA T CAN H APPEN 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 graduall[...]

27 SA FETY Operator S afety POTENTI AL HAZ ARD Im proper ly operat ing over obstac les. WHA T CAN H APPEN 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 when poss[...]

28 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CAN H APPEN T ires m ay float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an acc ident or overt 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 er . If it[...]

29 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV wit h improper t ires , or wit h improper or uneven t ire pr essur e. WHA T CAN H APPEN Use of impr oper tir es, or oper ation of the A T V wit h impr oper or uneven t ire pr essur e, could c ause loss of c ontr ol or acc ident. HOW T O A VOID TH E HAZ ARD Always use t he size and[...]

30 SA FETY Operator S afety POTENTI AL HAZ ARD Ov erloading t he A TV or car rying/ t owing cargo im properly . WHA T CAN H APPEN Ov erloading and t owing can caus e changes in v ehicle handling, which could lead t o loss of c ontr ol or an acc ident. HOW T O A VOID TH E HAZ ARD Never ex ceed t he st ated load c apacit y f or t his A T V . Cargo sh[...]

31 SA FETY Operator S afety 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 damage, including ( but no t limited to) bra kes, t hro ttle and stee ring systems. Saf e operat ion of t his r ider- activ e vehicle r equires good judgement and physic al skills . Pers ons wit h cognit ive [...]

32 SA FETY Fuel Safety 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 o- line. 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 is per[...]

33 SA FETY Safety D ecals and Locations W arnin g decals h ave been placed on the A TV for your protecti on. R ead and f oll ow th e ins t ructi on s o f th e decals on th e A TV careful ly . 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 on s of t he d ecals on the[...]

34 SA FETY Safety D ecals and Locations W ARNING 7077920 W ARNING Improper A TV use can r esu lt i n SEVER E INJUR Y or DEA TH ALW A YS USE AN APPRO VED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WIT H DRUGS OR ALCOHOL NEVER o pe rate : AL W A YS:[...]

35 SA FETY Safety D ecals and Locations Operat ing this A TV if you are under the age of 16 i ncreases your chan ce of severe i nj ury or d eat h. NEVER ope ra te t his ATV if y ou ar e under age 1 6. W ARNING 7078253 ALL WHE EL DRIVE SWITCH Do not push s witch to engage AW D if the rear wheels are spinning. T his may caus e sev ere drive shaf t an[...]

36 SA FETY Safe Riding G ear Always we ar c lothing suited to the t ype of riding. A TV riding requir es spec i al prote ctive clothing for c omfor t and to reduc e the cha nce of injury . 1. Helm et Y our he lmet is the most importa nt piece of prote ctive ge ar for sa fe riding. A hel met can p revent a sev ere head i nj ury . S elect an app rov [...]

37 FEATURE S AND CONTROLS Electr ical S witches Act ivat ing t he overr ide swit ch while t he thr ott le is open c an cause los s of cont rol, result ing in sev ere injury or deat h. Do not act ivat e the ov erride s witc h while the t hrot t le is open. W ARNING Ov errid e S wi tch (1 ) (Re ver se Speed Limite r) - This vehic l e is equipped with[...]

38 FEATURE S AND CONTROLS Light S witches The light sw itch is loca ted on the lef t hand leb ar (1). It’ s u sed t o tu rn the lights on and of f and to switch the lights fr om high bea m to low bea m. NOTE: The lights won’ t work unless the ke y is in the ON position and the shut-of f switc h i s in the RUN position. Indicator Li ghts W it h [...]

39 FEATURE S AND CONTROLS Throttle Lever Engine spee d and vehic le moveme nt ar e contro lled by pr essing the throttle le ver . The throttle le ver (1) is spring loaded. Engine spee d re turns to idle when the lever is releas ed. This A TV is equippe d with Pola ris Elec tronic Throttle Contr ol (ETC), whic h is designe d to reduc e the risk of a[...]

40 FEATURE S AND CONTROLS Br ake Lever The fro nt and rear brak es are app li ed by s queezi ng t he brak e leve r (1) towa rd the handle bar . The fro nt and rear brak es are hydra ulically a ctivate d disc type brak es th at are acti vat ed by o nl y one leve r . Alway s tes t brake lev er t ravel an d maste r cylinder f luid level be for e rid i[...]

41 FEATURE S AND CONTROLS Br akes Ch eck th e brake flu id l evel i n th e mas ter cyl in der b efore each u se o f the A TV . The ma ster cylinde r (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 t or window (2) on the top of the maste r cylinder . This “ey e” will appe ar da rk when the f luid le[...]

42 FEATURE S AND CONTROLS Park in g Brak e Setting the P arking Br ake 1. S queeze an d rel ease t he b rake l ever t wo o r thre e times, then squ eeze and ho ld . 2. Push the par k brake loc k (1) forw ar d to engage the bra ke. Rel eas e th e brake l ever . 3. T o relea se the parking brake loc k, sq ueeze and rel ease t he br ake leve r . It wi[...]

43 FEATURE S AND CONTROLS Auxiliary Brake The a uxiliar y foot brake ( 1), i s loca ted on the inside of the right floorboa rd and is oper ate d by the right foot. The auxiliar y brake serv es as a backu p t o t he m ain bra ke system i f the main syste m bec omes inopera tive. If the r ea r whee ls slide while using the a uxiliar y bra ke, r educe[...]

44 FEATURE S AND CONTROLS Choke The choke a ssists i n starting a c old engine. Ref er to the engine sta rting proc edur e on page 51 for corr ect choke and throttle se ttings 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 t hre e positions: OFF: For vehic le stora g[...]

45 FEATURE S AND CONTROLS 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 wa rd N: Neutral R: Rev er se Whe never the A TV is left unattende d, alwa ys place the tra nsmission in gea r a nd lock the pa rking bra ke. Mainta ining shift linkage adjustme nt is importa[...]

46 FEATURE S AND CONTROLS Recoil S tarter If the ba ttery has be en dra i ned o r dama ged a nd cannot star t the engine , use of the re coil star ter ( 1) will allow ve hicle ope ration until re pair s can be made . The rec oil star ter is locate d on the right side of th e mach in e. Polaris 4- cycle engine s are equippe d with automa tic decom p[...]

47 FEATURE S AND CONTROLS All W heel Dr ive (A WD) S ystem Po lari s 4-wheel d rive A TVs are equippe d with a unique, Polaris exc lusive, A WD syste m that’ s ac tivated by a sw itch (1) on the right handle bar . When the switc h is off , the A TV is in 2 whee l drive at all times. Wh en the switc h is on, the A T V is in A WD and t he A WD indi[...]

48 FEATURE S AND CONTROLS All W heel Dr ive (A WD) S ystem Di sengagi ng W heel H ubs Although the hubs norma lly disengage when ope ra ting in reve rse, one or both hubs may o ccasional ly rem ain engaged. If the h andlebars pul l to one side , it’ s likely tha t one fr ont hub is engage d . If both hubs a re engag ed, s teeri ng effort in creas[...]

49 OPERATION Br eak - In P er iod The br ea k-in per iod for your ne w 4-c ycle Polar is A TV is defined a s t he first ten hours of oper ation, or the time it ta kes to use the first two full tanks of ga soline. No single ac tion on your part is a s important a s following the proc edures for a prope r brea k-in. Caref ul tre atme nt of a new e ng[...]

50 OPERATION Pr e -Ride Inspection Use the f ollowing chec klist to verif y that your A TV is in proper wor king condition be fore each use. Item /Insp ectio n Procedu re 1. T ires - Che ck condition a nd pre ssure s. 2. Fuel and oil tanks - Fill both tanks to their prope r leve l s. 3. All bra kes - Che ck opera tion, ad justment and f luid level [...]

51 OPERATION Star ting the Engine S tar ting a Col d Engine 1. Place the tr ansmission in neutra l and loc k the par king bra ke. Make sur e the fue l t an k valve is on. 2. Sit on the vehicle a nd pull t he choke knob out until it stops (1 ). NOTE: I f the knob doesn’ t stay wher e positioned, incre ase the tension by r otating the te nsion adju[...]

52 OPERATION Star ting the Engine S tar ting a Col d Engine 3. Move the engine stop switch to RUN . NOTE: Do not pre s s the throttle w hile starting the engine . 4. T urn the ignition ke y past the ON position to engage the sta rter . Activa t e the star ter for a maximum of five sec onds, re l ea sing the key when the engine sta rts. If the engin[...]

53 OPERATION Star ting the Engine S tar ting a W ar m Engine W ar m engines do not normally requir e the use of the choke. Exce ssive use of the choke ca n cause the spa rk plug to become we t foule d. 1. Position the vehicle on a le vel surfa ce with the tra nsmission in neutr al. 2. Lock t he park in g brak e, t urn t he fuel t ank v alv e to ON [...]

54 OPERATION Hauling Cargo Acc essory r ac ks and hitc hes ar e a vailable fr om your Polar is dealer . Always re ad and unde rstand the load d istribution wa rnings 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 to the specific ations at the rea r of this man[...]

55 OPERATION Hauling Cargo Pro cedu res and Precau tio ns S REDUC E S PEED AND ALLOW GREA TER DIS T ANCE FOR BR AKING WHEN HAULING CAR GO. S CARGO WEIGHT DI STR IBUTION should be 1/3 on the f ront rack and 2/3 on the re ar r ac k. When ope rating ove r rough or hilly ter rain, re duce spe ed a nd car go to maintain sta ble driving c onditions. Carr[...]

56 OPERATION Driving Safely Driving Pr o cedures 1. Sit upright with both feet on the footr ests a nd 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 gear . 3. Check your surr oundings and determine your path of tr ave l. 4. Relea se t he par king brake . 5. Slowly depre ss the thrott[...]

57 OPERATION Driving Safely Making T urns Y our Polar i s A TV is equippe d with a solid re ar a xle, whic h drive s both re ar wh ee ls equally at a ll times. This me ans that the whe el on the outside of the turn must travel a gre ate r distanc e than the inside wheel whe n turning and the inside tir e must slip trac tion slightly . T o make a tu[...]

58 OPERATION Driving Safely Dr iving on Slippe r y Sur f aces 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 lo w thes e precaut io ns: 1. Slow down when e nter ing slippery a reas. 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, [...]

59 OPERATION Driving Safely Sidehilling Sidehilling ca n be a dange rous type of driving a nd should be avoided if at a ll possible. If you do e nter into a situa tion where sidehilling is neces sary , fol l ow t hes e precaut i ons : 1. Sl ow down. 2. Lea n into the hill, transf er ring your uppe r body weight towa rd the hill while kee ping your [...]

60 OPERATION Driving Safely Driving Uphill 25 _ Maximum 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 c ontr ol 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, an[...]

61 OPERATION Driving Safely Driving Uphill Whe neve r trav eling uphill, follow these pr ecauti ons : 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ ma ximum). 3. Kee p both fe et on the f ootrests. 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 pa[...]

62 OPERATION Driving Safely Driving Downh ill Whe never de scending 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 hicle. 3. Sl ow down. 4. Apply the brakes slightly to aid in slowing, using the single br ake leve r . NOTE: Fa miliar i z e yourse lf with opera tion of the a[...]

63 OPERATION Driving Safely T urning A round on a H ill If the ve hicle stalls while c limbing a hill, never ba ck it down the hill! One mane uver that c an be used whe n it’ s nece ssar y to turn ar ound while c limbing a hill is the K-turn: 1. Stop and lock the pa rking bra ke while ke eping body we ight uphill. 2. Lea ve tra nsmission in forwa[...]

64 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV c an ope rate through wa ter with a maximum re commende 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 termine wa ter depths a nd cur rent bef ore c rossing. 2. Choose a crossing wher e both banks have gra dual inc[...]

65 OPERATION Driving Safely Dr ivin g 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 . Sever e injury or death c an result if your v ehicle com es in cont act with a hidden obs tac le. Not all obst acles are [...]

66 OPERATION Driving Safely Dr ivin g in Rever se 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 sharp angle s in reve rse . 5. Ne ver ope n the throttle suddenly while ba cking. NOTE: Most Polar i s[...]

67 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible . If it’ s unavoida ble, 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 fuel [...]

68 EMISSION C ON TR OL SYST EMS Noise E mi ssion Contr ol System Do not modify the engine, i ntake o r e xhaust components, as doing so may af fec t complianc e with state and loca l noise level requir ements. Spar k Ar r estor Y our Polaris ve hicle ha s a spar k arre stor that was teste d and appr oved in accordance wi th the US DA F or est S erv[...]

69 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry powe r outlets provide 12V powe r for oper ating access ori es such a s hand held spot lights. Acce ssory outlets a re a vailable for all models. Contac t your P olar is dealer f or more informa tion. Po laris h as a wid e range of additi onal access ories avai lable for your A TV . See your Po[...]

70 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Hours of ope ration ar e based o n a 10 mph a vera ge. If ser vice is due a t 20 hours, the e quivale nt odomete r rea ding would be 200 mile s. P erform all s ervi ces at whi chever readi ng is reach ed first . Item Hours/ Mile s Frequency Remar ks Brake S ystem Pre- Ride Pr e-Ride In[...]

71 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks T a illigh t/b rak e ligh t Pre- Ride Pr e-Ri de Check operat ion dail y; ap- ply P olar is di electr ic gr ease to socket when r eplaced " L Air filte r , mai n elem ent W eekly W eekly Inspect ; repl ace as needed " T ransmi ssion oil 2[...]

72 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks Carbur etor f loat bowl 50 hr s. 6 mont hs Drai n bowl peri odicall y and pri or to stor age J Throt tl e Cable/ ETC Swit ch 50 hr s. 6 mont hs Inspect ; adjust ; lubr icat e; r eplace if necessar y L Choke (enr icher ) cable 50 hr s. 6 mont hs Ins[...]

73 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks J L Fuel system 100 hr s. 12 months Check for l eaks at t ank cap, li nes, fuel val v e, f ilt er , pump and car buret or; r e- place l ines ever y two year s J Fuel fi lt er 100 hr s. 12 mont hs Replace annual ly Radiat or 100 hrs. 12 m onths In s[...]

74 MAINTENANCE AND LUBRICATION Lubr ica tion R ecomm endations NOTE: Hour s are ba sed on 10 mph aver age. If se rvice is due a t 20 hours, the e quivale nt odomete r rea ding would be 200 mile s. P er form all serv ices at whi chev er readin g is reach ed firs t. Lubr ica tion C har t Key " More ofte n under seve re use, such a s wet or dusty[...]

75 MAINTENANCE AND LUBRICATION Lubr ica tion R ecomm endations (3) (1) (4 ) (2) (5) (9) (8) (6) (10) (7) 4 or 8 o’cl ock posit ion- ( end view)[...]

76 MAINTENANCE AND LUBRICATION Per iod ic Maintenan ce Recor d Use t he fol l owi ng ch art t o reco rd peri od ic m ain ten ance. Maintenance In terval Perfo rmed Se rv icing Date Ser vic ing Dealer or Pe rs on Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.[...]

77 MAINTENANCE AND LUBRICATION Per iod ic Maintenan ce Recor d Use t he fol l owi ng ch art t o reco rd peri od ic m ain ten ance. Maintenance In terval Perfo rmed Se rv icing Date Ser vic ing Dealer or Pe rs on Remarks[...]

78 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Pr emium 4 S ynth etic Oil Polaris Pre mium 4 All Sea son Synthetic e ngine oil has bee n specia lly for mulated for use in Polar i s 4-c ycle e ngines. It’ s a fully synthetic , high per forma nce , multi-visc osity oil designed to pr ovide the ultima te in lu bri cati on p erform anc[...]

79 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations E ngine Oi l Chec k 1. Position the machine o n a level surf ace. 2. Start the e ngine a nd let it idle for 20-30 se conds, t hen stop the engine . 3. Remove the dipstic k (1), whi ch is l ocat ed on t he left side of the vehic le. 4. W ipe the d ipstick dr y with a clean cl ot h. R ei n[...]

80 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Oil an d Filter Ch ange The r ec ommended oil ch ange inter val is 100 hours, 1000 miles, or every s ix m on th s, wh ich ever com es fi rst . Suggested br eak- in oil change is a t 20 hours, 200 miles, or one month, whiche ver c omes first. Sever e use oper ation requir es m ore f reque[...]

81 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Oil an d Filter Ch ange 9. Place shop towe ls beneath the oil filte r (1) . Using a n oil filter wre nch, turn t he filte r counte rc lockwise to remove. 10. Usi ng a clean , d ry clot h, cl ean the filte r sea ling surfa ce on the crank case. 1 1. Lubric ate the gasket on the new filte [...]

82 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations T ransm issio n Oil Check The tr ansmission lubrica nt level s hould be che cked e very six months or 1000 miles ( 1600 km), whic heve r come s first. Mainta in the oil leve l a t the bottom of the fill hole threa ds. Change tra nsmission oil annually . W e rec ommend the use of AGL Synt[...]

83 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Front Gearcase Oil Check The f ront gea rcase oil leve l s hould be che cked e very six months or 1000 miles ( 1600 km), whic heve r come s first. Mainta in the oil leve l a t the bottom of the fill plug threa ds. Change the oil annually . W e re commend the use of Polar is Angle Drive F[...]

84 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Drive Chain Polaris A TV drive cha ins are e quipped with o-r ing-sea led, perma nently greas ed pi ns and rol lers . Ho wever , th e out er su rfaces o f th e rol ler m us t be lubric ate d. Always inspe ct the dr i ve c hain prior to oper ating the vehic l e. Chec k for dama ged or mis[...]

85 MAINTENANCE AND LUBRICATION Adju stment s T oe Alignm ent Use the following proce dure to chec k the t oe alignme nt of t he vehic le. The re comme nded toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set t he handle bars in a stra ight-a head position. NOTE: The st eerin g frog can be us ed as an in di cato r of whether the ha ndleba rs are str[...]

86 MAINTENANCE AND LUBRICATION Adju stment s Br akes The front and re ar brake s are hydra ulic disc brakes, activa ted by moving the single brake le ver towar d t he handle bar . These br ake s are self -a djusting. The fo ll owi ng checks are recom men ded t o k eep th e brak e sys tem i n good oper ating c ondition. Check mor e often if bra kes [...]

87 MAINTENANCE AND LUBRICATION Adju stment s Br akes 1. Ch eck t he b rake sy st em fo r fl ui d l eaks. 2. Ch eck t he b rakes for ex cess iv e trav el o r spongy fe el. 3. Ch eck th e fricti on p ads fo r wear , dama ge and looseness. 4. Ch eck th e securi ty an d su rface condition of the disc. NOTE: Pads should be cha nged when worn to 3/64 ″[...]

88 MAINTENANCE AND LUBRICATION Adju stment s Steer in g Assem b ly The ste er ing assembly of the A TV should be che cked pe riodically f or loose nuts and bolts. If loose nuts and bolts are f ound, see your Polaris dea ler for se rvice bef ore ope ra ting the vehicle. Cam b er and Caster The ca m ber a nd caste r are non-a djustable. Rear S pring [...]

89 MAINTENANCE AND LUBRICATION Adju stment s Handlebars The h and leb ars can b e adj us ted for rid er preference. 1. Remove the handle bar cove r to access t he hand leb ar bolt s (1). 2. Loosen the four bolts. 3. Adjust the handle bar to the desir ed height. Be sure the handle bar s do not c ontac t the gas tank or any other pa rt of t he mac hi[...]

90 MAINTENANCE AND LUBRICATION Adju stment s Ca r bur etor IMPOR T ANT : Y our Polar i s A TV is c alibr ate d at the fa ctory for optimal pe rf orma nce at a ltitudes r anging f rom ze ro to 6,000 fee t (1800 m) and temper atures of +40 degr ee s F . (4 degr ee s C .) or higher . Above 6000 fe et (1800 m) the e ngine air/f uel mixture be comes ove[...]

91 MAINTENANCE AND LUBRICATION Adju stment s Wheel Rem o val 1. Stop the engine , plac e the tra nsmission in gear a nd lock the par king bra ke. 2. Loosen the whe el nuts slightly . 3. Eleva te t he side of the veh icle by plac i ng a suitable sta nd under the foot rest fram e. 4. Remove the whe el nuts and remove the whe el. Oper ating y our A T [...]

92 MAINTENANCE AND LUBRICATION Adju stment s Wheel Installation 1. Make sur e the t ra nsmission is in gea r with the par king brake lo cked . 2. P lace t he wh eel o n t he wh eel hub with the valve stem towar d the outside and the rota tion ar rows on the tire pointing to ward forward rot ati on. 3. Install the whee l nuts and f i nger tighten. 4[...]

93 MAINTENANCE AND LUBRICATION Adju stment s Fr ont Whee l Hub T ightening Front whee l bea ring tightne ss and spindle nut rete ntion are cr itical compone nt opera tions. All servic e must be pe rforme d 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 t o 1/8 ″ ( .3 cm) or le ss. Se[...]

94 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack Chec k the a mount of cha in slack in thr ee dif fe re nt locations by moving the ve hicle slightly f orwa rd to ga i n sla ck a t the top side of the r ear chai n. M easur e th e chai n sl ack at t he t ig ht est of t he t hree p os it io ns . At this point the chain should have [...]

95 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack 6. R ol l t he A TV forward or b ackward to adjust the cha in slack to the prope r tension. See the illustra tion for pr oper splice link clip ope ning position (1) . 7. T ig ht en t he eccen tri c lo cki ng bo lt s to 30 ft. lbs. (41 Nm) for ma chines without the hitc h and 45 ft[...]

96 MAINTENANCE AND LUBRICATION Engi ne Cooli ng System Coolant Level The re cover y bottle (1) is locate d 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 t he f l uid is cool) . The engine c oolant level is contr olled or mainta i ned b y the re cove ry system. The[...]

97 MAINTENANCE AND LUBRICATION Engi ne Cooli ng System Radiator Coolant L evel NOTE: This pr ocedure is re quire d only if the c ooling system has be en dr aine d for m ain ten ance and /o r repai r . Ho wever , if the re cove ry bottle has run dry , the leve l i n the radia t or should be inspecte d and co olan t add ed if neces sary . 1. Rem ov e[...]

98 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a halogen la mp, don’ t t ouch the lamp with ba re finger s. Oil from your skin le aves a re s idue , causing a hot spot tha t will shorten the life o f the lamp. Headlight L am p Replacement 1. Remove the wir e har ness connec tor from the back of the hea dlight. 2. Gra sp the bulb housing a[...]

99 MAINTENANCE AND LUBRICATION Lights T aillight /Br akelig ht Lamp Replacement If the taillight/br akelight does not wo rk the lamp may ne ed 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) and re place it with a ne w lamp. 3. T est [...]

100 MAINTENANCE AND LUBRICATION 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 re m ove the filte r . 3. Remove the f abric type pre -filter ( 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 ll t he [...]

101 MAINTENANCE AND LUBRICATION Spar k P lugs Spar k plug condition is indic ative of e ngine ope ra tion. The spar k plug firing e nd condition should be re ad af ter the engine ha s bee n wa rmed up an d th e vehi cle has b een dri ven at h ig her sp eeds . Imm edi at ely check t he spark p lu g for correct co lo r . 1. Normal The norma l i nsula[...]

102 MAINTENANCE AND LUBRICATION V eh ic le Imme rsi o n If it’ s impossible to take your A TV to a deale r befor e starting it, follow the steps outlined below . 1. Move the A TV to dry land or at the ver y least, to wa ter be low the footr ests. 2. Check the air box for a ny water . Drain an d dry it if wate r is prese nt. 3. T urn the fuel valv[...]

103 MAINTENANCE AND LUBRICATION Recoil Hou sing T o preve nt possible engine dama ge, always dr ain the r ec oil housing (1) a f t e ro p e r a t i n gt h eA T Vi nv e r yw e t conditions. This should also be done bef ore storing the A TV . W ate r will ente r the re coil housing if the star ter handle is disenga ged from the rope guide when under [...]

104 MAINTENANCE AND LUBRICATION PV T System The basic ope ra tion of the P olar is P VT system is depende nt on engine sp eed and vehi cle t orq ue requ irem ent s. As engi ne s peed i ncreas es, t he for ce e xerte d on the m ovable d rive shea ve by the flyweights also incr ea ses. This, in turn, incr ease s the amount of “pinc h” applie d t [...]

105 MAINTENANCE AND LUBRICATION PV T System PVT Dryi ng There m ay be som e ins tan ces when wat er is acci dent ly i ng est ed in to the PVT system. Use the following instruc tions to dry it out befor e oper ating: 1. Remove the d ra in plug and allow the wa ter to dr ain. Reinsta ll the dra in plug. 2. Start the engine an d shift the transmission[...]

106 MAINTENANCE AND LUBRICATION Spar k Ar r estor 1. Remove the ar restor cle an- out plug (1) fr om the bottom of the muf fle r . 2. Place the tr ansmission in neutra l and star t the engine. 3. Pur ge carbon fr om the system by momenta rily revving the e ngine seve ral time s. 4. If c ar bon is expelle d, cover or plug the exha ust outlet (2) and[...]

107 MAINTENANCE AND LUBRICATION Batter y Batt ery Remov al 1. Disconne ct the hold-down str ap holding the batte ry in position, and re move batte ry cover . 2. Dis conn ect t he b lack (negat iv e) bat tery cabl e firs t. 3. Disc onnec t the red (positive ) batte ry ca ble last. 4. Lift the batter y out of the A TV . Battery Installation Whe n ins[...]

108 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age When th e vehi cl e is pl aced i n s to rage fo r th ree mo nt hs or m ore, t he batte ry should be re moved, stored out of the sun in a cool, dry pla ce and te sted monthly . Befor e r eusing, take the ba ttery to your de aler f or testing a nd rec har ging. Power plug lea ds may need to b[...]

109 MAINTENANCE AND LUBRICATION Batter y Batt ery Cha rgin g NOTE: A lways ve rify batter y condition bef ore a nd 1-2 hours af ter the end of cha r ging. Stat e of Char ge Vo l t a g e Acti on Charge T ime* (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 of [...]

11 0 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 1 17 for the part number s of P olar is products. Cleaning th e A TV Kee ping your A TV cle an will not only improve its appe ara nce but it ca n also exte nd the life of va rious components. W ith a f ew precauti ons, your A TV can be cleaned m uch li ke an a utom obile. W ashin g th[...]

111 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 1 17 for the part number s of P olar is products. Exterio r Make nec essar y re pair s and then c lean the A TV thoroughly with mild soap a nd warm w ater to re move all dirt a nd grime . Don’ t use harsh dete rg ents or high pressure wa shers. S ome de ter gen ts det[...]

11 2 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 1 17 for the part number s of P olar is products. Flu id Levels Inspe ct the f ollowing fluid levels and c hange if nec essa ry: fr ont gea rc ase ; tran smission; front hubs; br ake f luid (c hange eve ry two yea rs or as re quired if fluid looks dark or conta minated[...]

11 3 MAINTENANCE AND LUBRICATION T r anspor ting the A TV Follow these proce dures when tra nsporting the vehic l e. 1. T urn off the e ngine and re move the key to prev ent loss during tra nsporting. 2. T urn the fuel valve of f. 3. Be s ure t he fu el cap , oi l cap and s eat are ins tal l ed correctl y . 4. Alwa ys tie the frame of the A TV to t[...]

11 4 SPECIFIC ATIO NS 2004 Scr am bler 500 4x4 Capac ities Body Styl e Gen III Gro ss V ehicle 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) ( Maxi mum) Rear R ack (A ccesso ry) 60 lbs . ([...]

11 5 SPECIFIC ATIO NS 2004 Scr am bler 500 4x4 Drive S ystem Dr ive Sys te m T ype PVT Shi ft T ype Side Le ver ( F-N- R) Ge ar Re duct ion - Reve rs e 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- Ring Fr ont T ir e s 2 3x7 - 1 0( 4p s i ) Rear Tires 22 x 1 1-10 ( [...]

11 6 SPECIFIC ATIO NS 2004 Scr am bler 500 4x4 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 utch Sprin g Helix /Spring Setting M[...]

11 7 POLARIS PRODUCTS Part No. Descr ipt ion Engine Lubr icant 2870791 Fogging O il ( 12 oz. Aer osol) 2871281 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( qt. ) 2871844 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( gal.) 2871567 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( 16 gal.) Gear case / T ransmi ssion Lubr ic[...]

11 8 TROUB LES HOOTIN G Contac t your P olar is dealer f or servic e if you’re una ble to identify solutions using the follow i ng ch ar ts. Dr ive Belt an d Cover Pr o blems Po ssib l e Cause Solution Dr ivi ng t he A TV ont o a p icku p o r tall trailer in hi gh ra nge . Shi ft t ra ns mi ss ion t o low r ange duri ng loa ding of the A TV t o p[...]

11 9 TROUB LES HOOTIN 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 te ry t o 12.8 VDC Loos e ba t te ry conne c t ions Ch eck all con n ectio n s an d tigh ten Loos e s ole noi d c onne c ti ons Ch eck all con n ectio n s an d tigh ten Engine T u[...]

120 TROUB LES HOOTIN G Engine Backfir es Po ssibl e Cause Sol uti on W ea k spa r k fr om s par k plugs In spect, clean an d/ or 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 c s or re pla c e plugs Ol d or non- re comm e nde d f ue l Re pla c e wi th new fue l In correctly in stalled sp ark p lu g wires Se e[...]

121 TROUB LES HOOTIN G E ngine S tops or Loses P ower Po ssibl e Cause Sol uti on Out of fuel Tu rn fuel v alve to reserv e, refu el Ki nked or plugge d fue l vent l ine In spect an d rep lace W ater p resent in fu el Repl ac e wit h new fue l Ove rus e of choke In sp ect, clean and /o r replace spark p lu g s Foul e d or de f e c ti ve s pa r k pl[...]

122 WARRANTY LIM IT ED W ARRANT Y Pol a ri s Sal es I nc ., 2100 Highwa y 55, Me dina , MN 55340, gi ves a SIX MONTH LI MI TED W ARRANTY on al l com pone nts of t he Pol a ri s Al l T e rr ai n V ehi cl e (A TV) aga ins t def ec ts i n ma te ri al or wor kma nshi p. Pol a r is al so gi ves a one yea r l imi te d war ra nty on t he f ina l dr ive c [...]

123 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TIO NS OF W ARRANTI ES AND REME DIE S ALL IM P LI ED W ARRANTIES ( INCLUDI NG BUT NOT LI MITED T O THE I MPLIED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD. POLARI S FUR THER DISCLAI MS ALL EX[...]

124 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE I F IT I S 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 ri [...]

125 INDEX A Accesso ries 6 9 ................... Adj ust ment s 85-95 ................ Ag e R estrictio ns 7 ................ Air F ilter 1 00 .................... Al l Whee l Dr ive 47- 48 ............. Au x iliary B rake 4 3 , 8 7 ............ A WD 47-48 ...................... B Ba tt er y 107-109 .................. Ba tt er y Char ging 108- 109 [...]

126 INDEX O Oil 78 .......................... Oi l Change 80- 81 ................. Oil F ilter C han g e 8 0-8 1 ............ OPERA TIO N 49-67 ............... Ope ra tor Sa fe ty 7-31 ............... Ov errid e S witch 3 7 ............... P Park in g B rake 4 2 ................. P a r k i n go na nI n c l i n e 6 7 ........... Pe ri odic M ai nte [...]