Polaris Scrambler 9922461 manual

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A card containi ng important A TV safety informa tion should be attached to the owner's man ual on the next page. If you canno t locate th is card, or if it has been removed, plea se call 1-8 00-342- 3764 for assistance. W ARNING The engine exhaust from th is product contains chemicals known to the Stat e of California to cause cancer , birth [...]

The text is printed on 100% recycled with 40% post-consume r waste (PCW).[...]

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 losing control. AL[...]

1 WELCOME Thank you for purch asing a Polaris vehicle, an d welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® W e believe Polaris sets a standard of excellence fo[...]

2 POLARIS, T HE W A Y OUT and SCR AMBLER ar e registere d tradema rks of Pola ris Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of pub lication. Due to constant improvements in the design and quality of production compo nents, some minor d[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 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 ha zard. W ARN ING A W ARNING indi cates a hazar[...]

5 INTRODUCTION Failure to hee d the w arnings and safety precautions con tained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate. This vehicle ha ndles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuve[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using yo ur key number) and mating it wi th one of your existi ng keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top prior ity for Polaris. Polaris strongly encourages you and any family member s who will be riding the A T V to take a training course. If you purchased a new Polaris A TV in the United S tates, your dealer provided instruction to y ou about the authorized A TV RiderCourse sm that is available [...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort an d to reduce the ch ance of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the[...]

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 Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make su[...]

10 SAFETY Safety W arnings Failure to operate the A TV pro perly can re sult in a collision , loss of control, accident or overturn, which may result in serious inju ry or death. Heed all safety warnings outlined in this section of the owne r ’s manual. See th e OPERA TION section of the owner ’ s manual for proper operati ng procedures. Operat[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and explosive u nder certain conditions. • Always exercise extreme cautio n whenever h andling gasoli ne. • Always refuel with the engine stopped, and outdoors or i n a well ventil ated area. • Do not smoke or allow open flames or sparks in or near the area where refu-[...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicl e without wearing an approved helmet and protective eyewe ar increases the risk of a serious inj uries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles o r face shield). Using Alcohol or Drugs Op[...]

13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewalks, paths, parking lot s and driveways) may adversely a ffect the handling of the A TV and co uld result in loss of control and accident or overturn. Avoid operating the A TV on pavement. A TV tires are design ed for off-road use. If it's una[...]

14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the foo trests during operation can reduce your a bility to co ntrol the ve hicle or cause loss of balance and ejection from the A TV . If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. Nev[...]

15 SAFETY Safety W arnings Descending Hill s Impr operly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hills as descri bed in th e owner's manual. NOTE: A special techn ique is required when braking while traveling down- hill. See page 48. • Always descend a [...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, rolling backwards or impr operly dismounting while climbi ng a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Keep body weight uphill. • Apply the single-le ver brake gradually . • Lock the parking bra[...]

17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, sl ippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippe ry or loose terrain. Always u se extra cautio n on rough, slippery or loose terrain. [...]

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow prope r operating procedures as outlined in this manual. See page 52. Before shifting into reverse gear , always check for obstacles or people behind the A TV . When i t's safe to proc[...]

19 SAFETY Safety W arnings Operating Over Obst acles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obst acles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme c aution and always follow proper ope rating proce dures as outlined [...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carryin g/towing cargo improperly may cau se changes in handling, which could cause loss of contro l or an accident. • Never exceed the stated load cap acity for this A TV . • Cargo should b e properl y distributed and securely attached. • Reduce speed when carrying car[...]

21 SAFETY Safety W arnings Operating a Damaged A TV Operating a da maged A T V can result in a n accident. After any overturn or accident, have a qual ified service dealer in spect the entire machine for possible damage, including (but not limited to) brakes, th rottle and steering systems. Physical Skills Safe operation of this rider-active veh ic[...]

22 SAFETY Safety Labels and Locations W arning labels hav e been placed on the ve hicle 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 labe ls on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or gr[...]

23 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper tha n 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 t eering becomes difficult. T o prevent loss of[...]

24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNIN G 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 ARNIN G Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or deat[...]

25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you are unde r the age of 16 increases your chan ce 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 under belt-clutch gu ard. T o prevent seriou s injury , do not operate [...]

26 FEA TURES AND CONTROLS Switches Override Switch This vehicle is equipped with a re verse sp eed limit er 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 resu lt in seri ous injury o r[...]

27 FEA TURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lig h ts on and of f. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. All Wheel Drive Switch See page 36 for all wheel drive information. Indicator Light s W ith the engine running, verify the[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV with sticking or impr operly operating throttl e controls could cause an accident. N ever start or oper ate an A TV that has a sticking or improperly operating th rottle. Always c ontact your deal er for service before operating the vehicle. Failure to check or ma intain proper operati on o[...]

29 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of brak ing, which could cause an accident. Neve r operat e th e A TV with a spongy-fee ling brake lever . Always contact your dealer for service before operating the vehicl e. Squeeze the brake lever toward the handleb ar to apply the front and r[...]

30 FEA TURES AND CONTROLS Parking Brake Locking the P arking 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 rele ase the parking brake lock, squeeze and release the brake lever .[...]

31 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , which could result in seri ous in jury or death. Never ba ck down a hill. Use caution when applying the a uxiliary bra ke. Do not aggressivel y apply the auxiliary brake when going forward. The rear wheels may [...]

32 FEA TURES AND CONTROLS Brake Fluid An over-full master cylinder may cause brake drag or b rake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid. Brake fluid is hygrosco pic, meaning it rapidly absorbs moisture from the air . The moistur[...]

33 FEA TURES AND CONTROLS Brake Fluid Hand Brake Check the brake fluid level in the master cylinder before eac h use of the vehi cle. The mas ter cylind er 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 th[...]

34 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine start- ing procedure on page 41 for cor- rect choke and th rottle settings during starting. 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[...]

35 FEA TURES AND CONTROLS Automatic T ransmission 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[...]

36 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The All Wheel Dr ive s ystem is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive and the A WD indicator light will be on. When in A WD, the demand drive unit will automaticall y en[...]

37 OPERA TION Failure to operate the A TV properly can resul t 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 period for your new Polaris A T V is the first ten hours o[...]

38 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 ve hicle. Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicl e. 3. Never carry a passenger on this A TV . 4. Engine ex haus[...]

39 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you ri de. Find out where the de signated riding areas are by con- tacting your Polaris dealer , a local riding club or local officials. Help keep [...]

40 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A T V before each use to make sure it's in safe operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 29 71 Brake fluid Ensure pr[...]

41 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 b rake. Tip : The starter interlock will preven t the eng ine from starting if the transmi ssion is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. S[...]

42 OPERA TION S t arting the Engine 9. T urn the ignition key past the ON position to engage the 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[...]

43 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit uprigh t with both feet on th e footrests and bo th hands on the handlebars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check you r surroundings and determi ne your path of travel. 6. Release the parking brake. 7. Sl[...]

44 OPERA TION T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly . T o turn, steer in the direction of the turn, [...]

45 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trai ls or loose gravel, or during freezin g weather , follow these precau tions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas. 3. Engage A WD before wheels begin to lose tractio n. NOTICE: Se[...]

46 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 c ontrol 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 terrain care fully before ascending an[...]

47 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proc edure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidab le , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. [...]

48 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. Shift body weight uph ill. 3. Drive straight downhill. 4. Slow down. Excessive speed wh en traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually . Applying the brakes too firmly may cause the rear wh[...]

49 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 parking brake while keepin g body weight uphil l. 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[...]

50 OPERA TION Driving Through W ater Y our A TV can operate through water with a maxi- mum recommended depth equal to the bottom of the footrests. Follow these pro- cedures 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 void operating thr[...]

51 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacle s: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly an d use ex tra cau tion when operating on unfamil[...]

52 OPERA TION Driving in Reverse Follow these precautions when operating in reve rse: 1. Always check for obstacles or peop le behind the vehi cle. 2. Always avoid ba cking downhi ll. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sh arp angles. 6. Never open the throttle suddenly . 7. Do not use the override switch[...]

53 OPERA TION Parking on an Incline A void parking on an incl ine if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve off. 25 ° maximum[...]

54 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to w ing cargo i mproperly ca n alter vehicl e 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 ca rgo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARG[...]

55 OPERA TION Hauling Cargo Never exceed the weight capacitie s sp ecified for your A TV on warning labels and in the specificati ons section of this manual. Always read and understand the load distri bution warning s on the rack and hitch warning labels. Never carry car go on th e front of the veh icle. Carg o should be eve nly distribute d and mo[...]

56 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that was teste d and qual[...]

57 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 intenanc e chart. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

58 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a  could result i n component failure an d cause an accident, which ma y result in se rious injury o r death. Always have an authorize d Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subje[...]

59 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) Battery 20 H Monthly 200 (320) Check terminals; clean; test [...]

60 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X Radiator (if applicable) 100 H 12 M 1000 (1600) Inspect; clean external surfaces X Cooling hoses (if applicable) 100 H 12 M 1000 (1600) Inspect for leaks X Engine mounts 100 H 12 M 1000 (1 600) Inspect Exhaust muffler/ pip[...]

61 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginni ng on page 57. Items not listed in the chart should be lubric ated at the Ge neral Lubrication interval. See page 109 for the part numbers of Polaris products. The a-arms and lower control arms are lubricated at [...]

62 MAINTENANCE Lubrication Guide F ront Prop Shaft Y oke Swing Arm Bushings Tie Rod Ends Fr o n t Hubs Ball Joint Axle Housin g 4 or 8 o'c lock position (e nd view)[...]

63 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W -50 oil. Follow the manufacturer's re[...]

64 MAINTENANCE Engine Oil Oil Level The oil dipstick is located on t he left side of the vehicle. 1. Position the vehicle on a level surface. Place the transmission in neutral. Lock the parking brake. 2. S tart the engine. All ow it to idle for 30 seconds. S top the engine. 3. Remove the dipstick. W ipe it dry with a clean cloth. 4. Reinstall the d[...]

65 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 57. 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. [...]

66 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[...]

67 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[...]

68 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 57. Maintain the oil level at the bottom of the fill hole threads. See page 109 for the part numbers of Polaris products. The fill plug is located on the left si de of the A TV , under the rear[...]

69 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the propshaft shield from the right side of the vehicle to access the fill plug. Remove the fill pl ug. 3. Remove the transmission drain plu g located on the bottom left-hand side and drain the oil into an app ropriate container . Discard used oil prop[...]

70 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Ch art beginnin g on page 57. Maintain the fluid level at the bottom of the f ill hole threads. See page 109 for the part numbers o f Polaris products. Fluid Recommendations Fluid Check The fill [...]

71 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the hand lebar . The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommende d to keep the brake system in good operating condition. Check more ofte[...]

72 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) to e out. W ARNING! Severe injury or death can result from improper toe alig nment and adjustment. Do not attemp t to adjust ti e rod alignment. All tie rod adjustments should be perf[...]

73 MAINTENANCE S teering Assembly The steering assemb ly of the A TV should be che cked periodica lly for loose nuts and bo lts. If loose nuts and bolts are fo und, see your Polaris dealer for service before ope rating the vehicl e. Camber and Caster The camber and caster are non-adjustable. Rear S pring The rear shock absorber spring is adjusted b[...]

74 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. W ARNING! Improper adjustment of th e 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. Follo w the adjustment procedures exac[...]

75 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr ope rly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and cou ld 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. Alway[...]

76 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 . W ARNING! Do not service axle nuts that have a cotter pin inst alled. See your Polaris deale r . 3. Place a suitable stand under the footrest frame to raise the wheel slight[...]

77 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)[...]

78 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre-filter from the main filter . W ash the pre- filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new main[...]

79 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[...]

80 MAINTENANCE Carburetor Y our Polaris A TV is calibrate d at the factory for optimal performan ce at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) or higher . Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power fo r ea c[...]

81 MAINTENANCE Drive Chain Drive Chain Lubrication Polaris A T V drive chains are equipped with o-ring-sea led, permanently greased pins and rollers. However , the outer surfaces of the roller must be lubricated . Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or dama ged rollers. Also check for [...]

82 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 - 1 0 mm) deflection.[...]

83 MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the A TV forward or backward to adjust the chain slack 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 hitch. 8[...]

84 MAINTENANCE Cooling System The engin e coolan t level is controlled, or maintai ned, 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[...]

85 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect 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 recove[...]

86 MAINTENANCE Light s Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in neutral. 3. Lock th e parking b rake. 4. Measure [...]

87 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 pro mptly . Always make sure lights are adjusted properly for best visibility . Headlamp Replacement When servicing a ha logen lamp, don'[...]

88 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 [...]

89 MAINTENANCE Spar k P l ug s S p ark Plug Recommendations Refer to the specifications section begi nning on page 1 14 for the recom- mended spark plug type and gap fo r your vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plugs. S p[...]

90 MAINTENANCE Spar k P l ug s S p ark Plug Condition Normal S park 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 tip[...]

91 MAINTENANCE V ehicle Immersion If your vehicle bec omes immersed, ma jor engine da mage can result if the machine is not thorou ghly inspected. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the vehicle out of the wat[...]

92 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 comb ustible materi als from the area . We ar eye protect ion and leather work gloves. Do not stand behind or in front of the vehicle wh ile purging[...]

93 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 ha s been precision balanced. Any modification will cause the system to be out of bala[...]

94 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 d[...]

95 MAINTENANCE P VT System P VT Drying There may be some instance s when 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. Al lo w the water to drain completely . Reinstall the dra in plug. 3. S tart the engine. Pla[...]

96 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 , always 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 s[...]

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

98 MAINTENANCE Battery Battery Inst allatio n 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 charging instructio ns on page 100 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the ba ttery i[...]

99 MAINTENANCE Battery Batter y S tor age 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 rge as needed to maintain a full char ge. Tip : Power[...]

100 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to preven t damage from leak- ing or spilled ele ctrolyte during cha r ging. See pa ge 97. 2. Char ge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1[...]

101 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 batter y) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-[...]

102 MAINTENANCE Cleaning and S torage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various componen ts. NOTICE: High water pre ssure may damag e components. Polaris recommend s washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, in[...]

103 MAINTENANCE Cleaning and S torage W ashing the V ehicle If a high pressure water system is u sed for clea ning (n ot recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: If an informational or graphic label becomes illegible or c[...]

104 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 c[...]

105 MAINTENANCE Cleaning and S torage Sto r a g e Tips NOTICE: S tarting the engine durin g the storage perio d will disturb the protective film created by fogging and damage coul d 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 102. Stabilize [...]

106 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as recommended in th e Periodic Maintenance Chart beg inning on page 5 7. • Demand drive unit (front gearcase) • T ransmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test s[...]

107 MAINTENANCE Cleaning and S torage Sto r a g e Tips Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommende d in the Periodic Maintenance Chart beginn ing on page 57. Battery Storage See pages 99-100 for storag e and charging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV[...]

108 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 b rake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to prev ent loss during transporting. 7. Always tie the frame of the A T V to[...]

109 POLARIS PRODUCTS Part Number Description Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synth e tic 2 W-50 4-Cycle Oil (q t./.95 l) 2876245 PS-4 PLUS Per formance Synthe tic 2W -50 4-Cyc le Oil (gal ./3.8 l) Gearcase / T ran smission Lubricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) 2[...]

110 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 49). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or u se low range (if equipped) more frequently . Insufficient warm-up at low ambie nt tempera- ture[...]

111 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to S t 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[...]

112 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , S t alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recomme nded 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 Solut[...]

113 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 wi th new fuel Overuse of choke Ins pect, cl ean a nd/or replace spark plugs Fouled or defective spark plugs Inspec t, clean and/or replace s[...]

114 SPECIFICA TIONS * Based on EU Directive 76/432/EC Scrambler 500 4X4 Maximum W eight Capacity 275 lbs. (125 kg) (includes weight of opera- tor , cargo and accessories) Dry W eight 566 lbs. (257 kg) Fuel Capacity 4 gal. (15.1 l) Engine Oil Capacity 2 qts. ( 1.9 l) T ransmission Oil 32 oz. (946 ml) Demand Drive Fluid Ca pacity 9 oz. (265 ml) Coola[...]

115 SPECIFICA TIONS Jetting Chart Clutching Ch art Scrambler 500 4X4 Driving System T ype Automatic PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (F/N/R) Gear Reduction, Reverse 4 .74:1 Gear Reduction, Forward 3.06:1 Drive Ratio, Front 3.818:1 Drive Ratio, Final 2.77:1 Drive Chain 520 O-Ring T ires/Pressure, Front 23 x 7-10 (4 psi/27[...]

116 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elepho ne 763-542-0500 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN DIRECTIVES TEST /[...]

117 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s. This warranty c[...]

118 W ARRANTY W ARRANTY COVERAGE AND E XCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND REMEDIE S The Polaris l imited warrant y excludes any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This warranty also does not cover any A T[...]

119 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIES This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su rface im perfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude co mpensation[...]

120 W ARRANTY ALL IMPLIED W ARRANTIES (INCLU DING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AN D FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER D ISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some state s do not al low limi- tations o[...]

121 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LO CA- TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries. Dea[...]

122 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private ci tizen, to be kept and used outside of the country in which the vehicle was o riginally purchased, all warrant y coverage will be denied. Notice If your vehicle is registered outside of the country where it was [...]

123 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited war ranty is in addition t o the Polaris sta ndard limited wa rranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conform s with applica- ble U.S. Environ[...]

124 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem edy for breach of this limited warranty shall be, at the excl usive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REMEDIES SE T FOR TH IN THIS LIMITED W ARRANTY A RE THE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH O[...]

125 MAINTENANCE LOG Present this section of your ma nual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

126 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

127 INDEX A Air Filt er . . . . . . . . . . . . . . . . . . . . . . 78 All Wheel Drive Swi tch . . . . . . . 27, 36 All Whe el Drive Syste m . . . . . . . . . . 36 B Battery . . . . . . . . . . . . . . . . . . . 96-101 Charging (Conventional) . . . . 100 Charging (Sealed) . . . . . . 100-101 Fluid (Conventional) . . . . . . . . . 99 Installat ion .[...]

128 INDEX G Gasoline Handling . . . . . . . . . . . . . . 11 Gear Selector . . . . . . . . . . . . . . . . . . 35 Gloves . . . . . . . . . . . . . . . . . . . . . . . . 9 H Handlebar A djustment . . . . . . . . . . . 74 Hauling Cargo . . . . . . . . . . . . . . . 54-55 Headlamp Replac ement . . . . . . . . . . 87 Headlight Beam Adjus tment . . . . [...]

129 INDEX S Side Panel Removal . . . . . . . . . . . . . 71 Sidehilling . . . . . . . . . . . . . . . . . . . . . 47 Signal Wo rds . . . . . . . . . . . . . . . . . . . . 4 Spark Arres tor . . . . . . . . . . . . . . . . . . 92 Spark Plugs . . . . . . . . . . . . . . . . . 89-90 Spring Adju stments, Rear . . . . . . . . . 73 Starting the Eng ine . [...]