Polaris 500 2X4 International manual

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

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

2 POLARIS and POLARIS TH E W A Y OUT are regi stered tradem arks of Polaris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discrep[...]

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

4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal inju ry hazard. W ARNING A W ARN ING indicates a hazardous[...]

5 INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This vehicle is not a toy and can be hazardous to operate. A collision or ro llover can occur quickly , even during routine maneuvers, if you fail to take proper precautions. • Read this owner ’ s manual. Understand [...]

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

7 SAFETY Safety T raining When you purchased your new Polaris vehicle, yo ur dealer offered a hands-on safety training course. Y ou were also provided with printed materials that explain safe operatin g procedures. Review this informa- tion on a regular basis. If you purchased your vehicle from a party other than a Polaris dealer , please request f[...]

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

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

10 SAFETY Operator Safety Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’ s manual. See the OPERA TION section of the owner ’s manual for proper operati ng procedures. Read and [...]

11 SAFETY Operator Safety Handling Gasoline Gasoline is highl y flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling g asoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling [...]

12 SAFETY Operator Safety Never consume alcohol o r drugs before or while operating this vehicle. Keep both hands on the handl ebars. Keep both feet on the footrests. Never carry a passenger . Th e purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.[...]

13 SAFETY Operator Safety Never carry a passenger on the rear ra ck. Ejection from the vehicle or contact with moving components can result in serious injury or death. Operating on paved surfaces ma y serious ly affect the handling and control of the Quadricycle and could result in loss of control, acci dent and/or injur y . Avoid sudden turns or s[...]

14 SAFETY Operator Safety Always follow the procedures outli ned in this manual for turnin g. Never turn sharply at excessive speeds, which can lead to vehicle overturn. See page 37. Never attempt jumps or other stunts. Always follow the pro cedures outlined in this manual for drivin g through water . Never drive through deep or fast-flowing water [...]

15 SAFETY Operator Safety Always follow the pro cedures outlined in this manual for driving on hills. See page 39. Never operate on hills too steep for this vehicle or for your abilities. Practice on smal ler hills before attempting larger hills. Avoid climbing hills steeper than 25 ° . Always follow the pro cedures outlined in this manual for dri[...]

16 SAFETY Operator Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Always travel slowly when operating on unfamiliar terrain. U se extra cautio n. Always follow the procedures outlined in this manual for driving in reverse. See page 45. Use caution when operating on rough, slippery or loos[...]

17 SAFETY Operator Safety Never operate this vehicle on a frozen body of water . Never modify a Quadricycle through imprope r installation or use of accessories. Never exceed the stated load capacity fo r your vehicle. Cargo must be properl y distributed and securely attached. Reduce speed and foll ow the instructions in this manual for carrying ca[...]

18 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your p rotection. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual differ from the labels on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or graphi[...]

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

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

21 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under age 16. 7175374 Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch gu ard. T o prevent serious injury , do not operate vehic[...]

22 FEA TURES AND CONTROLS Switches Override Switch This vehicle is equipped with a re verse speed limiter sys tem. 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, which may result in seri ous injury o r dea[...]

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

24 FEA TURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. Failure to check or maintain proper operation of the th rottle system can result in an accident if the thrott le lever sticks during opera tion. Check the lever for proper op[...]

25 FEA TURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydrau lically activ ated disc type brakes that are ac tivated by only one lever . Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any spongi[...]

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

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

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

29 FEA TURES AND CONTROLS T 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 the vehic[...]

30 OPERA T ION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Rea d 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 vehicle is the first ten hou[...]

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

32 OPERA T ION Safe Operation Practices 1. Complete the recommen ded safety training be fore operating this vehicle. See page 7. 2. Do not allow anyone un der 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical disabi lities to oper- ate this ve hicle. 3. Never carry a passen ger on this vehic le. 4. Engine exh[...]

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

34 OPERA T ION 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 the parking brake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. Sit [...]

35 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 engin e starts. NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating[...]

36 OPERA T ION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright. Kee p your feet on th e footrests. Keep both hands on the handlebars. 3. Squeeze the brake lever . 4. Star t the engine and allow it to warm up. 5. Shift the transmission into gear . 6. Check your surroun dings and determine your path of travel. 7. R[...]

37 OPERA TION T urning the V ehicle T o turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. The same leaning technique should be used for turn ing in reverse. Practice making turns at slow speeds before attempting to turn at faster speeds. T urning improperl[...]

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

39 OPERA TION Driving Uphill Braking and handling are greatly affe cted when operating in hilly ter- rain. Improper pro cedure could cau se loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Always check the ter- rain carefully before ascending any[...]

40 OPERA T ION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void hills with excessively slippery or lo[...]

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

42 OPERA T ION T urning Ar ound 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 wh ile keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hicle, or on the le[...]

43 OPERA TION Driving Through W ater Y our Polaris vehicle can operate through water with a maximum recom- mended depth eq ual to the bottom of the footrests. Follow these proce- dures when operating through water: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks have gradual inclines. 3. A void op[...]

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

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

46 OPERA T ION Hauling Cargo Overloading the vehicl e or carrying or to wing cargo i mproperly can al ter vehicle handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these precaution s when hauling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO. [...]

47 OPERA TION Hauling Cargo Load Distribution Accessory racks and hitches are available from your Polaris dealer . Read and understand the load distrib u- tion warnings l isted on the vehicle warning labels. Never exceed the specified weights. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as [...]

48 OPERA T ION Parking on an Incline A void parking on an incline. If it' s unavoidable, follow these precau- tions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Always block the rear wheels on the do wnhill side. 5. T urn the fuel valve off.[...]

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

50 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main tenance chart . Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the ne[...]

51 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked wi th a  could result in component failure and cause an accident, wh ich may result in se rious injury o r death. Always have an authorized Pola ris de aler perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subje[...]

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

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

54 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Exhaust muffler/ pipe 100 12 M 1000 (1600) Inspect Q E Spark[...]

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

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

57 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 50. Always change the oil filter whenever changing 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. S[...]

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

59 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenev er the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch 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 press[...]

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

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

62 MAINTENANCE Brakes Brake Fluid An over-full master cyl inder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Once open, a bottle of brake fl uid absorb s moistu re from the air , which causes the boiling temperature of the brake fluid to drop. This can lea [...]

63 MAINTENANCE Brakes Brake Fluid (Hand Brake) Check the brake fluid level in the master cylinder be fore each use of the vehicl e. The master cyl inder is located on the left handlebar . Maintain the fluid level 1/4" (6 mm) below the top edge of the master cylinder . Do not overfill. 1. Position the vehicle on a level surface. Make sure the h[...]

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

65 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent is 3-6 mm toe out. W ARNING! Severe injury or death can result from improper to e alignment and adjustment. Do not attempt to adju st tie ro d alignment. All tie rod adjustments should be performed by an authorized Pol[...]

66 MAINTENANCE S teering Assembly Check the steering assembly of the vehicle periodically for loose nu ts and bolts. If loose nuts and bolts are found, se e your Polaris dea ler for service before operating the vehicle. Rear Suspension The rear suspension spring preload and shock compression damping may be adjusted to suit different riding condi- t[...]

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

68 MAINTENANCE Handlebars W ARNING! Improper adjustme nt of the handleba rs or incorrect torqui ng of the adjuster block tightening bolts can caus e limi ted steering or loosenin g of the handlebars, resulting in loss of co ntrol and serious injury or death. Follow the adjustment procedures exactly , or see your Polaris dealer fo r service. The han[...]

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

70 MAINTENANCE Drive Chain Drive Chain Lubrication The drive chai ns are equipped wit h o-ring-sealed, permanently greased pins and rollers. Howeve r , the outer surfaces of the roller must be lubri- cated. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or dama ged rollers. Also check for correct[...]

71 MAINTENANCE Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three different 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 shou ld have 3/16"-3/8" (5 mm - 10 mm) deflection. N[...]

72 MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or back- ward 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 hitc[...]

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

74 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[...]

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

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

77 MAINTENANCE Ti r e s Operating your vehicle with worn tires, i mproperly infl ated tires, no n-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follow all tire maintenance procedures as outlined in this manual a nd on the labels on the vehicle. Al [...]

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

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

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

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

82 MAINTENANCE Spar k P l ug s Sp ark Plug Recommendations Refer to the specifications sect ion beginning on page 1 02 for the recom- mended spark plug ty pe and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Sp ark Plug Inspection Check the spark plug[...]

83 MAINTENANCE Spar k P l ug s Sp ark Plug Condition Normal Spark Pl ug 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 [...]

84 MAINTENANCE V ehicle Immersion If the vehicle stops while fully su bmerged, major engine damage can result if the machine is not thoroughl y inspected. T ake the vehicle to your dealer before starting the eng ine. If it's impossible to take your vehicle to a dealer before starting it, fol- low the steps outlined below . 1. Move the vehicle [...]

85 MAINTENANCE S p ark A rrestor Failure to heed the following warnings whil e servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protec tion and leather work gloves. Do not stand behind or in fro nt of the vehicle while purging. N[...]

86 MAINTENANCE P VT System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a hig h speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of balanc[...]

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

88 MAINTENANCE P VT System PVT Drying There may be some instances 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. Allo w the water to drain completely . Reinstall the drain plug. 3. Start the engine. Place th[...]

89 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosio n and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains sul[...]

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

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

92 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three mo nths 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 storag e and recharge as needed to mainta in a full charge. Tip : Power p[...]

93 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electroly te during charging. See page 90. 2. Charge 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 1.270 o[...]

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

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

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

97 MAINTENANCE Cleaning and St orage 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 years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chro[...]

98 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps NOTICE: S tarting the engine during the storage perio d will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Se e page 95. Stabilize the [...]

99 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Fluid Levels Inspect the fluid levels. Change fluids as recommende d in the Periodic Maintenance Chart beginn ing on page 50. • T ransmission • Brake fluid (change every two years and any time the fluid loo ks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. T reat th[...]

100 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Inspect and Lubricate Inspect all cables and lu bricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 50. Battery Storage See page 92-94 for storag e and char ging procedures. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Us[...]

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

102 SPECIFICA T IONS * Based on EU Directive 76/432/EC Scrambler 500 2X4 Maximum W eight Capacity 3 05 lbs. (138 kg) (includes weight of opera- tor , cargo and accessories) Dry W eight 530 lbs. (240 kg) Fuel Capacity 3.5 gal. (13.2 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmission Oil 1 1.3 oz. (334 ml) Coolant 2.25 qts. (2.13 l) Front Rack Capac[...]

103 SPECIFICA T IONS Jetting Chart Clutching Chart Scrambler 500 2X4 Driving System T ype PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (F/N/R) Gear Reduction, Reverse 3.05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 12/36 76P Drive Chain 520 O-Ring T ires/Pressure, Front 23 x 7-10 (4 psi/27.6 kPa) T ires/Pressure, Rear 22 x [...]

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

105 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Starting out going up a steep incl ine Use low range (if equipped) or turn around using the K- turn (see page 42). Driving at low 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 ambient te mpera- tures[...]

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

107 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended 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 Solution[...]

108 TROUBLESHOOTING Engine Stop s or Loses Power Possible Cause Solution Out of fuel T urn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Overuse of choke Inspect, cl ea n and/or replace spark plugs Fouled or defective spark plug(s) I nsp ect, clean and/or replace s[...]

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

110 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIE S ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P A R- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE TWO YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIM S ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . So[...]

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

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

11 3 INDEX A Air Filte r . . . . . . . . . . . . . . . . . . . . . . 80 B Battery . . . . . . . . . . . . . . . . . . . . 89-94 Charging (Conventional) . . . . . 93 Charging (Sealed) . . . . . . . . 93-94 Fluid (Conventional) . . . . . . . . . 92 Installation . . . . . . . . . . . . . . . . 91 Removal . . . . . . . . . . . . . . . . . . 90 Storage [...]

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

11 5 INDEX T Throttle Cable Freeplay . . . . . . . . . . 67 Throttle Leve r . . . . . . . . . . . . . . . . . . 24 Tires . . . . . . . . . . . . . . . . . . . . . . 77-79 Tread Depth . . . . . . . . . . . . . . . 77 Wheel and Hub Tightening . . . . 77 Wheel Installation . . . . . . . . . . . 78 Wheel Nut Torqu e . . . . . . . . . . 79 Wheel Removal[...]