Polaris Scrambler 9921620 manuale d’uso

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1 WELC O ME Thank you f or purc ha sing 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 exc iting line of utility a nd re cr e ationa l produc ts. S Snowmobiles S All- ter ra in ve hicle s (A TVs) S Quadri cycl es S RANGER utility vehicle s S V ict ory m o to rcycl es W e belie ve Pola ris se[...]

2 Copyr ight 2007 Pol a r is Sa l e s Inc . All inf or m a t ion c ont a ine d wi thi n thi s publ ic at ion i s ba se d on t he la te st pr oduct i nfor ma ti on a t the t ime of publ ic at ion. Due t o c ons ta nt imp ro v emen ts in the desig n and q u ality o f pr oduct ion com pone nts , som e minor d iscrepan cies may resu lt betw een the act[...]

3 TABLE OF CONTENTS Know Y our V ehicle 5 ......................... Safety 6 ..................................... Features and Contr ols 31 ..................... Operation 41 ................................. Em ission Contr ol S ystems 59 ................. Maintenance 60 .............................. Specifications 108 ..........................[...]

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5 KNOW YOUR VEHICLE As the opera tor of the vehicle , you are re sponsible for your persona l saf ety , the saf ety of others, and the prote ction of our environme nt. Read a nd understa nd your owner ’ s ma nual, which include s valuable infor mation about all aspec ts of your vehicle , including safe ope ra ting proce dures. Ride r e sponsibly [...]

6 SA FETY Operator S afety The f ollowing signal wor ds and symbols appe ar throughout this manua l and on your ve hicle. Y our saf ety is involve d when the se words and symbols ar e used. Beco me fa miliar with their mea nings bef ore re ading the manual. The safet y alert s ymbol , on y our vehic le or in t his manual, aler ts you t o the pot en[...]

7 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 injury or death. A P ol aris Quadricycl e is not a toy and can be hazar dous t o operat e. T his v ehicle handles diff erent ly than ot her vehicles, s uch as mot orcycl es and cars. A collision or rollover c an occur quic kly , [...]

8 SA FETY Operator S afety W ARNING Serious injur y or deat h can r esult if you do not f ollow thes e inst ruct ions and pr ocedures , whic h are out lined in fur ther det ail within your owner ’ s m anual. S Rea d this manual and a ll labels c are fully , and follow the oper ating proce dures desc ribed. S Neve r oper ate a Quadr icycle without[...]

9 SA FETY Operator S afety S Always ha ve the Quadr icycle inspe cted by an a uthorize d P olar is dealer i f it ’ s b een invol ved in an acci dent. S Ne ver ope rate on hills too steep for the Q uadr i c ycle or f or your abili- ties. Pra ctic e on sma ller hills befo re a ttempting lar ger hills. S Alwa ys follow pr oper pr ocedur es for c lim[...]

10 SA FETY Operator S afety S W et br ake s may have re duced stopping a bility . T est your bra kes af ter lea ving wate r . If ne cessa ry , apply them lightly se ver al times to allow frict io n to d ry out t he pad s. S Always che ck for obstac les or people be hind the vehicle be fore ope r- ati ng i n revers e. When i t ’ s s afe to pro cee[...]

11 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Operat ing t his Q uadricycle without proper inst ruction. WHA T CA N HAPPEN The r isk of an accident is great ly inc reased if t he operat or does not know how t o operat e the Q uadr icycle properly in different sit uations and on diff erent t ypes of ter rain. HOW T O A VOID THE HAZ ARD Nev[...]

12 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Carr ying a passenger on a Quadri cycle. WHA T CA N HAPPEN Carr ying a passenger great ly reduces t he operat or ’s ability to balance and control t he Q uadri cycle, which could c ause an accident and injury t o the oper ator and/ or passenger . HOW T O A VOID THE HAZ ARD Never c arry a pas[...]

13 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Operat ing t hi s Quadricycle without wearing an approved helm et, eye prot ect ion and prot ect ive clot hing. WHA T CA N HAPPEN Operat ing a Q uadricycle without an approved helmet inc reases t he ris k of a s evere head injur y or death in t he event of an accident . Oper ating wit hout ey [...]

14 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Operat ing t he Q uadricycle af ter consum ing alcohol or dr ugs. WHA T CA N HAPPEN Consumpt ion of alc ohol and/or dr ugs could ser iously aff ect oper ator 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 dr ugs be[...]

15 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD At tem pting wheelies , jum ps and other s tunt s. WHA T CA N HAPPEN At tem pting s tunt s inc reases the c hance of an ac cident , including an over tur n. HOW T O A VOID THE HAZ ARD Never at tem pt wheelies, jumps, or other s tunt s. A v oid exhibit ion driving. W ARNING POTENTI AL HAZ ARD F[...]

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 CA N HAPPEN Removing ev en one hand or f oot c an reduce abilit y t o cont rol t he vehicle or c ould cause los s of balance and ejec tion f rom t he Quadri cycle. If t he operator ’ s foot is not f[...]

17 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Failu re t o use e xt ra caut ion when operat ing on exces sively r ough, slippery or loos e terr ain. WHA T CA N HAPPEN Opera ting on e xcessivel y 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 overt urn. HOW T O [...]

18 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating on ex cess ively s teep hills . WHA T CA N HAPPEN The v ehicle may ov ert urn. HOW T O A VOID THE HAZ ARD Never operat e on hills t oo steep f or t he Quadri cycle o r for your abilities. Never operat e the Q uadricycle on h ills steeper t han 25 _ . Prac tic e on smaller hills bef [...]

19 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD T rav eling downhill impr operly . WHA T CA N HAPPEN Im proper ly desc ending a hill could caus e loss of cont rol or overt urn. HOW T O A VOID THE HAZ ARD Always f ollow proper procedur es for t rav eling down hills as desc ribed 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 CA N 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 THE HAZ ARD N e v e ra t t e m p tt ot u r nt h e Quadricycle a round on any hill until you’v e mast ered t he tur nin[...]

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 CA N HAPPEN The v ehicle could ov ert urn. HOW T O A VOID THE HAZ ARD Maint ain st eady speed when climbing a hill. If all for ward speed is lost: Keep your weight uphill. Apply t he single lev er brak e gr[...]

22 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im proper ly operat ing over obstac les. WHA T CA N HAPPEN Oper ating ov er obst acles c ould cause los s of cont rol or ov ert urn. HOW T O A VOID THE 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 Operat ing t he Quadr icycle thr ough deep or f ast-f lowing water . WHA T CA N HAPPEN T ires m ay float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an accident or over tur n. HOW T O A VOID THE HAZ ARD Avoid operating t he Quadricycle t hrough deep or f ast-f low[...]

24 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Operat ing t he Quadr icycle with i mproper modif ications. WHA T CA N HAPPEN Im proper inst allat ion of acces sories or m odific ation of t he Quadricycle m ay c ause changes in handling which could lead t o an accident . HOW T O A VOID THE HAZ ARD Never modif y the Quadri cycle t hrough imp[...]

25 SA FETY Operator S afety W ARNING Leaving t he keys in t he ignit ion can lead t o unauthor ized use of the v ehicle res ulting in s erious injur y or deat h. A lways rem ove the ignit ion key when t he vehic le is not in use. W ARNING Af ter any over tur n or ac cident, have a qualif ied serv ice dealer inspect the ent ire v ehicle f or poss ib[...]

26 SA FETY Fuel Safety W ARNING Gas oline is highly f lamm able and explosiv e under cer t ain condit ions. S Always ex ercis e ext reme c aution whenev er handling gasoline. S Always r efuel wit h t he engine st opped, and out doors 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 ueli[...]

1 2 27 SA FETY Safety D ecals and Locations W arning d ecals have been placed on t he vehicle for your protecti on. Read an d fo ll ow t he i ns tru cti on s o f th e decal s o n t he veh icl e careful ly . If any o f th e decal s dep ict ed i n th is m anu al d iffer from t he decal s o n your vehicl e, always read and foll ow t he inst ructi ons [...]

3 28 SA FETY Safety D ecals and Locations Gene r al W arni ng (3) W ARNING Im proper A TV use can r esult in SEVERE INJUR Y or DEA TH AL WA YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WI TH DRUGS OR ALCOHOL NEVER operat e: S wit hout proper t rai ning or inst ruct ion S at speeds too fa[...]

4 6 5 29 SA FETY Safety D ecals and Locations No P assenger W arning (4) W ARNING NEVER r ide as a passenger . Passenger s can cause a los s of c o ntro l, re su ltin g in SEVERE INJUR Y or DEA TH. A g e1 6W a r n i n g( 5 ) W ARNING Oper ating thi s A TV if you are under t he age of 16 incr eases your chance of severe inj ury or death. NEVER opera[...]

30 SA FETY Safe Ri ding Gear Always we ar c lothing suited to the t ype of riding. Quadr i cyc le riding re quires spec ial protec tive clothing f or co mfor t and to re duce the chan ce of i nj ury . 1. Helm et W eari ng a h elm et can p reven t a s evere head injury . Whe never r iding a Polar is vehic le, alway s wear a hel m et t hat m eets o r[...]

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 esult ing in sever e injury or deat h. Do not act ivat e the ov erride s witc h while the t hrot t le is open. Ov errid e S wi tch (1) (Rev er se Speed Limite r) - This vehic l e is equippe d wit[...]

32 FEATURE S AND CONTRO LS 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 th e lights on and of f a nd to switch the lights fr om high bea m to low bea m . NOT E: T he lights won’t work unless the k ey is in t he ON posit ion and the s hut- off swit ch is in the RUN position. Indicator Li ghts [...]

33 FEATURE S AND CONTRO LS Throttle Lever W ARNING Do not start or operat e a Quadricycle wit h st icking or improperly 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 m aintain pr oper op[...]

34 FEATURE S AND CONTRO LS Br ake Lever W ARNING Oper ating t he vehic le with a s pongy brak e lever c an result in loss of br aking, whic h could caus e an accident . Never operat e t he vehicle wit h a spongy -f eeling brake lev er . The fro nt an d rear b rakes are app li ed by s queezi n g th e brake leve r (1) toward the ha ndleba r . The fro[...]

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 befor e each us e of the veh icle . The maste r cylinde r (1) is l ocat ed o n th e left han dl ebar . The f luid leve l can be seen thr ough an indica t or window (2) on the top of the maste r cylinder . This “e ye” will appe ar da rk whe n the flui[...]

36 FEATURE S AND CONTRO LS Park in g Brak e W ARNING Oper ating t he vehic le while the par king brak e is engaged could result in an accident and serious injur y or death. A lways chec k to be sure t he park ing brake is dis engaged befor e operat ing. Locking th e P arking Br ake 1. S queeze an d rel ease t he b rake l ever t wo o r thre e times,[...]

37 FEATURE S AND CONTRO LS Auxiliary Brake W ARNING Aggres sively apply ing the r ear brak e when backing downhill m ay cause r ear t ipover , whic h could res ult in s erious injur y or deat h. Use caut ion when applying t he auxiliar y brak e. Do not aggress ively apply t he auxiliar y brak e when going for ward. T he rear wheels m ay sk id and s[...]

38 FEATURE S AND CONTRO LS Choke The choke a ssists in starting a cold engine . Refe r to the engine star ting proc edur e on page 43 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 t he l eft s i de of the vehic le, below the f ende r . It has thre e positions: OFF: For vehic le stora [...]

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 l e. F: For wa rd N: Neutral R: Rev er se CAUTION Shif ting gear s wit h the engine s peed above idle or while t he vehicle is m oving could c ause t ransm ission dam age. T o change gear s, s top t he[...]

40 FEATURE S AND CONTRO LS Recoil S tarter If the batter y has bee n drained or dama ged and ca nnot start the engine , use of the rec oil starte r (1) will allow ve hicle ope ration until re pairs can be ma de. The rec oil star ter is loca t ed on the right side of th e mach in e. Polaris 4- cycle engine s are equippe d with automa tic decom pres [...]

41 OPERATION Br eak - In P er iod The bre ak- in period for your new Polar is Quadricyc l e is the first t en hours of oper ation, or the time it take s to use the fir st two full tanks of gasoline . No single ac tion on your par t is as importa nt as following the proc edures for a pr oper bre ak-in. Caref ul trea tment of a new engine a nd drive [...]

42 OPERATION Pr e -Ride Inspection W ARNING If a proper ins pect ion is not done bef ore eac h use, s evere injur y or deat h could res ult. A lways ins pect t he vehicle bef ore eac h use to ens ure it ’ s in pr oper 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, 7[...]

43 OPERATION Star ti ng the Engi ne 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 par king bra ke. NOT E: T he [...]

44 OPERATION Star ti ng the Engi ne 7. Move the engine stop switch to R UN. NOT E: Do not press t he t hrot tle while st art ing t he engine. 8. T urn the ignition key pa st the ON position to enga ge the sta rter . Activa t e the star ter for a maximum of five sec onds, rele asing t he key whe n the engine starts. 9. If the engine doe s not start,[...]

45 OPERATION Driving Safely Driving Pr o cedures 1. Sit upright with both feet on the footrests a nd both hands on the handle bars. 2. Start the e ngine a nd allow it to wa rm up, then shift the tra nsmission into gear . 3. Check your surr oundings and dete rmine your pa th of trave l. 4. Relea se t he par king bra ke. 5. Slowly depre ss the thrott[...]

46 OPERATION Driving Safely Hauling Cargo Acc essory r ac ks and hitche s are ava ilable f rom your Pola ris deale r . Always re ad and unde rstand the loa d distribution wa rnings on all warni ng l abel s, and nev er exceed t he speci fi ed weig ht cap ac itie s for the vehic l e. Maxim um T owin g Capacit ies Refe r to the spec i fic ations at th[...]

47 OPERATION Driving Safely Hauling Cargo W ARNING Hauling cargo im proper ly can alt er v ehicle handling and may cause los s of c ontr ol or brak e inst ability and r esult in ser ious injury or deat h. Always f ollow thes e precaut ions when hauling cargo: S REDUCE SPEED AN D ALLO W G REA TER DI ST ANCE F O R BRAKING WHEN HAULING C ARGO . S CARG[...]

48 OPERATION Driving Safely Making T urns Y our Polar is vehic le is equippe d with a solid re ar a xle, which dr ives both re ar w heels e qually a t all time s. This mea ns that the whee l on the outside of the turn must trave l a grea ter distanc e than the inside wheel whe n turning and the inside tire must slip tr ac tion slightly . T o make a[...]

49 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 t rail s or lo os e gravel, or du ring freezi ng weat her , fo ll ow t hese precau ti on s: 1. Slow down when e nter ing slippery a rea s. 2. Mai nt ai n a hi gh lev el o f alert nes s, read in g th e tr ail and av oi di ng qui ck, [...]

50 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[...]

51 OPERATION Driving Safely Driving Uphill W ARNING Brak ing and handling are gr eatly affec ted when oper ating in hilly ter rain. I mproper pr ocedure c ould cause los s of c ontr ol or overt urn and r esult in s erious injur y 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[...]

52 OPERATION Driving Safely Driving Uphill Whe neve r trave ling uphill, follow the se pr ecaut io ns : 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ ma ximum). 3. Kee p both feet on the footre sts. 4. T ransfer your we ight forwa rd. 5. P roceed at a st eady rat e of sp eed and t hro ttle opening. 6. Rema in ale rt and be prepa [...]

53 OPERATION Driving Safely Driving Downh ill Whe never de scending a hill, follow the se pr ecau ti on s: 1. P roceed di rect ly d own h ill. 2. T ransfe r your weight to the re ar of the vehic 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 t he[...]

8’ (2. 4 m) 54 OPERATION Driving Safely T urning A round on a Hill If the ve hicle stalls while c limbing a hill, never ba ck it down the hill! Use the K- turn to turn ar ound. 1. Stop and lock the pa rking bra ke while ke eping body weight uphill. 2. Lea ve the tra nsmission in forwa rd and shut of f the e ngine. 3. Dismount on the uphill side o[...]

55 OPERATION Driving Safely Dr ivi ng Thr ough W ater Y our vehicle ca n opera te through wa ter with a maximum re commende d depth equa l to the bottom of t he footr ests ( 1). Follow 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[...]

56 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 o n. Be con st ant l y alert f or hazards s uch as l og s, rock s and l ow han gi ng bran ches . W ARNING Sever e injury or deat h can r esult if y our vehic le comes in c ontac t with a hidden obs tac le. Not all obs [...]

57 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 shar p angle s in rever se. 5. Ne ver ope n the throttle suddenly while ba cking. W ARNING Failur e to[...]

58 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 unavoidable , follow th ese p recaut io ns : 1. T urn the engine of f. 1. Place the tr ansmission in gear . 2. Lock the par king bra ke. 3. Always block the rea r wheels on the downhill side. S ee illustra tion. 4. Shut of f the fuel [...]

59 EMISSION C ON TR OL SYSTEMS Noise E mi ssion Contr ol System Do not modify the engine, intake o r exha ust components, as doing so may af fe ct complia nce with gove rnmenta l noise leve l requir ements. Exhaust Em issi on Contr ol S ystem The emissions fr om the exhaust of this vehic le are c ontrolled by engine design, including fa ctory-se t [...]

60 MAINTENANCE Per iodic Maintenance C hart Care ful periodic ma intena nce will help ke ep your vehic l e in the safe st, most relia ble condition. Inspe ction, adjustment a nd lubrication o f importa nt components ar e explaine d in t he per iodic m ainte nance c hart. Ins pect , clean , lu bri cate, ad ju st and repl ace parts as necess ary . Wh[...]

61 MAINTENANCE Per iodic Maintenance C hart Maintena nce Char t Key " P erform t hes e pro cedures m ore freq uent ly fo r vehi cl es su bj ected t o seve re use. E Emission-r ela ted servic e (Failure to conduc t this maintena nce will not void the emissions warr ant y but may af fect e missions. ) J Have an aut ho rized P ol aris d ealer p e[...]

62 MAINTENANCE Per iodic Maintenance C hart Item Maint enance Inter val (w hichev er c omes f irs t) 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 t erminals ; c lean; tes t " Front gear c ase oil (if applic able) 25 H Monthly 250 ( 400) Inspec [...]

63 MAINTENANCE Per iodic Maintenance C hart Item Maint enance Inter val (w hichev er c omes f irs t) 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 f ler/ pipe 100 H 12 M 1000 (1600) Ins pec t J E Spark plug 100[...]

64 MAINTENANCE Lubr ication Recom m endations Always che ck and c hange f l uids and l ubric ate grea seable c omponents at the inter vals outlined in the Periodic Ma intena nce Cha rt beginning on page 60. Items not listed in the cha rt should be lubrica ted at the Gene ral Lubric ation interva l. NOT E: T he a-ar ms and lower c ontr ol arms ar e [...]

65 MAINTENANCE Lubr ication Recom m endations (1) (2) (3) (4)[...]

66 MAINTENANCE Engi ne Oil Alwa ys che ck and change the e ngine oil at the interva ls outlined in the P eriod ic M ai nt enance C hart b egi nning on page 60. Always change the oil filter whe never c hanging oil. Oil R ecom menda tions Polar is rec ommends the use of Polaris PS- 4 P LU S Perf ormanc e Synthetic 2W -50 4-c ycle oil or a simila r oi[...]

67 MAINTENANCE Engi ne Oil Oil an d Filter Chan ge 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 th e 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 [...]

68 MAINTENANCE Engi ne Oil Oil an d Filter Chan ge 9. Plac e shop towe ls bene ath the oil filte r . Using an oil filte r wre nch, turn the filte r (1) c ounterc lockwise a nd re move. 10. Lubrica te the gasket on the new filte r with a film of new engine oil. Check to ma ke sure the gasket is in good condition. Also make sur e the gasket from the [...]

69 MAINTENANCE Engi ne Oil Oil an d Filter Chan ge Oil Pump Pr iming This priming proc edur e m ust be perform ed wh enever t he oi l ho se conne ction betw een the oil tank and pump inle t has bee n disconne cted. 1. Clamp or pinch of f t he 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 a[...]

70 MAINTENANCE T r ansm ission Oil Alwa ys che ck and change the tr ansmission oil at the interva l s outlined in the Periodic Mainte nance Cha rt beg inning on page 60. Mainta in the oil level within the SAFE oper ating range on the dipstick. W e re commend the use of Pre mium AGL Synthe tic Gea rc ase Lubric ant. See page 1 1 1 for the par t numb[...]

71 MAINTENANCE T r ansm ission Oil Refe r to the specif ications se ction beginning on pa ge 108 for tran sm i ss io n oi l capaci ty . Oil Chan ge 1. Position the vehicle on a leve l surf ace. 2. P lace a drain p an ben eath t he tra nsmission oil drain plug area. 3. Loosen the j am nut ( A). 4. T urn the adjuste r bolt (B) in to allow the re mova[...]

72 MAINTENANCE Drive Chain The drive c hains are e quipped with o-ring-se aled, permane ntly gre ased pi ns an d rol l ers. Ho wever , t he o ut er su rfaces o f th e rol ler m ust be lu bri cat ed. Always inspe ct the dr i ve c hain prior to ope ra ting the vehic l e. Chec k for dama ged or missing o-r ings or damage d roller s. Also che ck f or c[...]

A B 73 MAINTENANCE T oe A lignm ent W ARNING Sever e injury or deat h can r esult f rom impr oper t oe alignment and adjust ment . Do not at t empt t o adjust t ie rod alignm ent. A ll tie r od 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 alignment of the vehicle. The re comm[...]

74 MAINTENANCE Br akes The front and re ar brake s are hydr aulic disc bra kes, activa t ed by moving the single brake le ver towar d the handleba r . These bra kes are self -adjusting. The fo ll owi ng check s are reco mm ended t o k eep t he brak e sys tem in good oper ating condition. Chec k more of ten if bra kes ar e used hea vily under norma [...]

75 MAINTENANCE Br akes 1. Ch eck t he b rake sy st em for fl ui d l eaks . 2. Ch eck t he b rakes fo r exces si ve t ravel 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. NOT E: P ads should be c hanged when worn t o 3/64 ″ (. 1 cm). Auxiliary Brake [...]

A B C 1/16 ″ to 1/8 ″ (1.5-3 mm) A 76 MAINTENANCE Steer ing Assem bly The ste ering a ssembly of the vehicle should be che cked pe riodica lly for loose nuts and bolts. If loose nuts and bolts ar e found, see your Polaris dea l er f or ser vice befor e operating the vehic l e. Cam ber and Caster The ca m be r and ca ster are non- adjustable . R[...]

77 MAINTENANCE Handlebar s W ARNING Im proper adjust ment of t he handlebars or incorr ect t orquing of the adjus ter bloc k t ightening bolt s c an cause lim ited s teer ing or loosening of t he handlebars , r esult ing in loss of c ontr ol and possible s erious per sonal injury or deat h. F ollow the adjus tm ent procedur es exact ly , or see you[...]

78 MAINTENANCE Car bur etor IMPOR T ANT : Y our Pola ris vehic le is ca librate d at the fa ctor y for optimal pe rf orma nce at altitudes r anging from z ero to 6,000 fe et (1800 m) and temper ature s of +40 degr ee s F . (4 degre es C .) or higher . Above 6000 fe et (1800 m) the e ngine air /fue l mixture be comes ove rly rich a nd the engine los[...]

79 MAINTENANCE Wheels W ARNING Oper ating y our vehic le with wor n tir es, im properly 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 result ing in ser ious injury or death. Maint ain proper t ire pr essur e as desc ribed on t he decal on your vehicle and in y our[...]

80 MAINTENANCE Wheels Wheel Installation 1. Place the transmission in ge ar and loc k the parking b ra ke. W ARNING Im proper ly installed wheels can adver sely affec t t ire wear and vehicle handling, which can r esult in s erious injur y or deat h. Always ens ure t hat all nut s ar e tor qued to s pecif icat ion. Do not serv ice axle nut s t hat [...]

81 MAINTENANCE Wheels Fr ont Whee l Hub T ightening Front whee l bea ring tightne ss and spindle nut rete ntion are c ritica l 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 less. See illustr ation. W ARNI[...]

82 MAINTENANCE Rear Dr ive Chain S lack CAUTION Adjust ing or oper ating t he vehic le with im proper r ear dr ive chain slack c an result in sever e damage t o the t rans miss ion and drive component s. Always m ake sur e the s lack is wit hin the s tat ed specif icat ions. Chec k the a mount of cha in slack in thre e dif fe re nt locations by mov[...]

83 MAINTENANCE Rear Dr ive Chain S lack 6. Roll the vehic le forwa rd or bac kwar d to adjust the c hain sla ck to the proper te nsion. See the illustra tion for pr oper splic e link clip ope ning position (1). 7. T ig ht en t he eccen tri c lo cki ng b ol ts to 30 ft. lbs. (41 Nm) for machine s without the hitc h and 45 ft. lbs. (61 Nm) for ma chi[...]

84 MAINTENANCE Engi ne Cool ing 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 maintaine d betw ee n the minimum and maximum mar ks on the bottle (whe n the fluid is cool). The engine c oolant l eve l is contr olled or mainta ined by the re cove ry system. The rec overy system c[...]

85 MAINTENANCE Engi ne Cool ing System W ARNING Esc aping st eam can c ause sev ere burns . N ever r emove 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[...]

86 MAINTENANCE Lights Whe n servic ing a haloge n lamp, don’ t touch the la mp with bar e finger s. Oil fro m your skin le aves a residue , causing a hot spot tha t 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 lens es becom e dirt y during nor mal ope[...]

87 MAINTENANCE Lights T aillight/Brakelight L am p Replacement If the taillight/bra kelight 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 an d set aside f or re assembly . 2. Remove the lamp (1). 3. Apply dielec t ric gr ease to the so cket and i ns tal l [...]

88 MAINTENANCE Filter System s Air Filter Service 1. Rem ov e t he seat , r eleas e the clips, and remove the air box cover . 2. Loosen the clamp a nd re m ove the filte r . 3. Remove the f abric type pre -filter ( 1) fr om the main f ilter ( 2). W ash the pre -filter i n soapy w ater , then rinse and l et dry . 4. Reinsta ll the pre- filter ove r [...]

89 MAINTENANCE Spar k P lugs S par k Plug R ecomm endati ons CAUTION Using non-r ecom mended spar k plugs c an result in s erious engine damage. Alway s use P olaris- recom mended s park plugs . Ref er to t he spec ific ations s ect ion beginning on page 108 . Refe r to the specif ications se ction beginning on pa ge 108 for the re comme nded spark[...]

90 MAINTENANCE Spar k P lugs Spar k Plug Inspectio n Normal Plug The norma l i nsula tor tip is gray , tan or light brown. Ther e will be few combustion deposits. The ele ctrodes are not burne d or erode d. This indica t es the prope r t ype and hea t range f or t he engine a nd the servic e. NOT E: T he t ip should not be whit e. A whit e insulat [...]

91 MAINTENANCE V eh icl e Imme rsi on CAUTION If your v ehicle becom es imm ersed, major engine dam age can result if t he mac hine is not t horoughly ins pected. T ake t he vehicle t o your dealer bef ore st ar ting t he engine. If it’ s impossible to take your Qua dricycle to a dea ler befor e starting it, follow the step s outlined below . 1. [...]

92 MAINTENANCE PV T System The basic ope ration of the P olar i s PVT system is dependent on engine sp eed and v ehi cle t orqu e requi rem ents . As en gi ne sp eed i ncreases , t he for ce e xer ted on the m ovable dr ive sheave by the flyweights also incr ease s. This, in turn, incre ases the a mount of “pinch ” a pplied to the drive be lt. [...]

93 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 failur e may oc cur at a high s peed. The PVT syst em has been precisio n balanced. Any modif icat ion will cause [...]

94 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 servi ce on the spa rk arrestor wh ile the system is hot. Exhaust syst em tem perat ures ca n reach 1000 ° F . A llow component s t o cool s ufficient ly bef ore pr o[...]

95 MAINTENANCE Batter y Y our vehicle may have e ither a sea led batter y , which re quire s little mainte nance , or a conve ntional batte ry . A seale d battery c an be identif ied by its flat c overs on the top of the ba ttery . A c onventiona l batte ry has six f iller ca ps on the top of the batter y . Conve n tiona l Batte r y Always ke ep ba[...]

96 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 , alway s disc onnect t he negat ive (blac k) cable f irst . W hen reins talling t he bat ter y , alway s connec t t he negativ e (black ) cable las t. Batt ery R[...]

97 MAINTENANCE Batter y Battery Installation Using a ne w batter y that has not bee n fully cha r ged ca n damage the bat tery an d resu lt i n a sho rt er life. It can al so h ind er vehi cle per for manc e. Follow the batte ry cha rging instr uctions on page s 99-101 bef ore installing the batte ry . 1. Ensur e that the batte ry is fully ch ar ge[...]

98 MAINTENANCE Batter y Batter y Stor age Whe never the ve hicle is not used for a pe riod of thre e m onths or more, remo ve t he bat tery fro m t he v ehicl e, en su re th at i t’ s fu ll y charged, and st ore it out o f the s un in a coo l, dry pl ace. C h eck batt ery vo lt age each mo nt h du rin g st orag e and recharge as needed t o mai nt[...]

99 MAINTENANCE Batter y Batte ry Fluid (C onventiona l Batte r y) A poorly ma intained ba ttery will dete riora te ra pidly . Chec k the batte ry 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 ater . T ap w ater conta i ns miner als that are harmful to a batte ry . Batter y Char[...]

100 MAINTENANCE Batter y Batter y Char ging (Sealed B attery) The f ollowing batte ry cha r ging instructions a pply only to the in st all ati on o f a s ealed b att ery . R ead al l in st ruct io ns b efore proceed in g with the installation of this batter y . The seale d batter y is alre ady f illed w ith elec trolyte a nd has be en sea led and f[...]

101 MAINTENANCE Batter y Batter y Char ging (Sealed B attery) 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 ime* (Us ing cons tant cur rent char ger @ standar d amps spec ified on top of battery ) 100% 12.8- 13.0 volt s None, check at 3 mos. fr om dat[...]

102 MAINTENANCE Cleaning a nd Stor age See page 1 1 1 for the par t numbers of Polaris products. W ash ing th e V e hicle Kee ping your vehic l e cle an will not only improve its appe ar anc e but it ca n also exte nd the lif e of var ious compone nts. CAUTION High water pr essur e may dam age vehicle c omponent s. Polar is recom mends washing t he[...]

103 MAINTENANCE Cleaning a nd Stor age W ash ing th e V e hicle If a high pr essur e wa ter syste m is used for c leaning (not recom men ded ), exerci s e ext reme cau ti on . Th e wat er may d amag e components and could remove pain t and decal s. A void d irecting t he wa ter str ea m at the f ollowing items: S Wheel b earin gs S Radiator S T ran[...]

104 MAINTENANCE Cleaning a nd Stor age Chr ome W heel C are (i f equipped) P roper mai nt enance wil l pro tect ch rom e wh eels fro m corros io n, pres erve wheel l i fe and en su re a ”li ke new” ap pearance fo r man y years . NOT E: Chr ome wheels ex posed t o road salt (or s alt in t he air in coast al areas ) are m ore sus cept ible to c o[...]

105 MAINTENANCE Cleaning a nd Stor age Sto ra ge Ti ps See page 1 1 1 for the par t numbers of Polaris 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 f ogging and damage c ould occur . Nev er st art t he engine during t he st orage per iod. Clean t he Exterio r Mak e any necess[...]

106 MAINTENANCE Cleaning a nd Stor age Sto ra ge Ti ps Flu id Levels Inspe ct the fluid le vels. Add or cha nge fluids as r ecomme nded in the Periodic Mainte nance Char t beginning on page 60. S Dema nd drive unit ( front gea rcase ) S Rear g earcase (i f equ ip ped ) S T ransmission S Bra ke fluid (c hange e very tw o yea rs and a ny time the flu[...]

107 MAINTENANCE Cleaning a nd Stor age Sto ra ge Ti ps Inspe ct a nd Lubric ate Ins pect al l cab les an d l ub ricat e al l areas o f th e veh icl e as reco mm end ed in the P e riodic Mainte nance Cha rt beg inning on page 60. Batte ry S tora ge See pa ges 98-101 for stora ge a nd cha rging pr ocedur es. Sto rage A rea/C overs Set the tire pre ss[...]

108 SPECIFIC ATIO NS 2008 Scr am bler 500 2X 4 Inter national Capac ities Body Styl e Gen III Ma ximum W ei ght Capa c it y 305 l bs . ( 138 kg) Fue l 3.5 ga l. (13. 2 l ) Transm issio n O il 1 1.3 oz . ( 334 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 ccesso ry ) 30 l bs . ( 13.6 kg) (M axi mum) Rear R ack[...]

109 SPECIFIC ATIO NS 2008 Scr am bler 500 2X 4 Inter national Drive S ystem Dr ive Sys te m T ype PVT Shi ft T ype Side Le ve r (F- N-R) Ge ar Re duct ion - Reve rs e 3.05/ 1 Gear R ed u ction - F orw ard 2. 68/1 Fi nal D riv e (ratio) 12/ 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 12- 10 (3 ps i ) Sus pe[...]

11 0 SPECIFIC ATIO NS 2008 Scr am bler 500 2X 4 Inter national 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 Char t Altitude Shi ft W eight Dr ive C lutch Sprin g Driven Cl utch Sprin g Helix /[...]

111 POLARIS PRODUCTS Part No. Descr ipt ion Engine Lubr icant 2870791 Fogging O il ( 12 oz. Aer osol) 2876244 PS-4 P LUS Per form ance Synthet ic 2W - 50 4-Cycl e Oil ( qt. ) 2876245 PS-4 P LUS Per form ance Synthet ic 2W - 50 4-Cycl e Oil ( gal. ) Gear case / T ransmi ssion Lubr icant s 2873602 Prem ium AGL Synt heti c Gearcase Lube ( qt. ) 287360[...]

11 2 TROUB LES HOOTIN G Contac t your P olar is dea l er f or servic e if you’re una ble to identify solutions using the follow i ng c har ts. Dr ive Belt and Cover Problem s Possibl e Cause Solut ion Dr ivi ng onto a pic kup or tall trailer in hig h ran ge Shi ft t ra ns mis si on to l ow ra nge duri ng loa ding of the Qua dri cyc le t o pre ven[...]

11 3 TROUB LES HOOTIN G Engine Doesn’t T u r n 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 cha r ge ba tt er y to 12. 8 VDC Loos e bat te ry conne ct ions Ch eck all con n ectio n s an d tig h ten Loos e sol enoi d c onne c ti ons Ch eck all con n ectio n s an d tig h ten Engine T [...]

11 4 TROUB LES HOOTIN G Engine Backfir es Po ssibl e Cause Sol uti on W e a k s pa rk f rom s par k plugs In spect, clean an d/ or repl ace sp ark p lug s In correct sp ark plu g g ap o r heat rang e Se t gap to spe cs or r epl a c e pl ugs Ol d or non- re comm ende d fue l Re pla ce wi th new fue l In correctly in stalled sp ark p lu g wires See y[...]

11 5 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 resen t in fu el Repl ac e wit h ne w fue l Ove rus e of choke In sp ect, clean and /o r rep lace spark p lu g s Foul e d or def ec ti ve s par k p[...]

11 6 WARRANTY LIM IT ED W ARRANTY Pol a r is I ndust ri e s Inc . , 2100 Highwa y 55, Medi na , MN 55340, give s a TWO YEAR LI MI TED W ARRANTY on al l compone nts of t he Pola ri s Quadr ic ycl e a gai nst de fe ct s in ma te ri al or wor kma nshi p. Thi s war ra nty c ove r s the pa r ts a nd la bor cha r ge s for r epa ir or rep lacemen t of def[...]

11 7 WARRANTY LIM IT A TIONS O F W ARRANT IES AND REMEDIES ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LI MITED T O THE IM- PLIED W ARRANTI ES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TI CU- LAR PURPOSE) ARE LI MITED IN DURA TION T O THE ABOVE TWO YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAI MS ALL EXPRESS W AR- RA N TIE S N OT S T A T ED IN[...]

11 8 MAINTENANCE LOG Use t he fol l owi ng ch art t o reco rd peri od ic m ain ten ance. DA TE MILES ( KM) TECHNICIAN SER VICE PER FORMED / CO MM ENTS[...]

11 9 MAINTENANCE LOG DA TE MILES ( KM) TECHNICIAN SER VICE PER FORMED / CO MM ENTS[...]

120[...]

121 INDEX A Ag e R estrictio ns 7 ................ Air F ilter 8 8 ..................... Au x iliary B rak e 37 , 7 5 ............ B Ba tte r y 95-101 ................... Ba tte r y Cha r gi ng (C onve nti onal ) 99 .. Ba tte r y Cha r gi ng (Se a le d ) 100- 101 .... Ba tte r y Flui d (Conve nti onal ) 99 ..... Battery In stallatio n 9 7 .........[...]

122 INDEX N Noi se Emi ss ion Contr ol Syst em 59 ... O Oi l Change 67- 69 ................. Oil F ilter C h ang e 6 9 .............. Oi l Pump Pri ming 69 .............. Oi l Rec omme ndat ions 66 ........... Oi l, Engi ne 66-69 ................. Oi l, T ra nsm is si on 70- 71 ............ Ope ra tor Sa fe ty 6-25 ............... Ov errid e S witc[...]