Polaris Scrambler 9921777 manual

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W ARNING Improper vehicle use can result 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 [...]

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 cannot locate th is card, or if it has be en removed, please call 1-800-342- 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 de[...]

1 WELCOME Thank you for purch asing 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) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excellence for a ll u[...]

2 POLARIS and POLARIS THE W A Y OUT are registere d trademarks 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 compo nents, some minor discrep[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 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 ARNING A W ARNING indicates a hazardo[...]

5 INTRODUCTION Failure to hee d the w arnings and safety pre cautions contained 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 maneuv[...]

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 with one of your existing keys. The ignition switch [...]

7 SAFETY Safety T raining A TV safety training is a top priority for Polaris. Wh en you purch ased your new A TV , your dealer instructed you o n the authorized A TV RiderCourse sm availa ble to you and y our e ligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and y our eligible f[...]

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 chance 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 T V properly can re sult in a coll ision, 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 manu al for proper operati ng procedures. Opera[...]

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. Ne[...]

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 described in the own er's manual. NOTE: A special techn ique is required when braking while traveling down- hill. See page 50. • Always descend a h[...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, rolling ba ckwards or improperly 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 54. Before shifting into reverse gear , always check for obstacles or people behind the A TV . When it's safe to proce[...]

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 a cles. A vo id operati ng over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper ope rating proce dures as outlin[...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carrying/towing cargo imprope rly may cause changes in handling, which could cause loss of contro l or an accident. • Never exceed the stated load capa ci ty 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 labe ls have been plac ed 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 dif fer from the labels on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or gra[...]

23 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILL S 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 [...]

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

25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you ar e under the age of 16 increases your chance 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 ha zard under belt-clutch gu ard. T o prevent serious injury , do not operate v[...]

26 FEA TURES AND CONTROLS Switches Override Switch This vehicle is equipped with a re verse sp eed 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, 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 th e lights 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. All Wheel Drive Switch See page 36 for all wheel drive information. In[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV with sticking or impr operly ope rating throttle 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 spon gy brake leve r can result in loss of braking, 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 operati ng the vehicle. 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 release 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 injury or death. Ne ver back down a h ill. 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 each u se 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[...]

34 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 for correct ch oke and throttle settings during start- ing. 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 t[...]

35 FEA TURES AND CONTROLS Automatic T r ansmission 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 whil[...]

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 front hubs will automatically engage any[...]

37 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System Disengaging A WD Although the hubs n ormally disengag e when operating in reverse, one or both hubs may occasionally rema in engaged. If the handleba rs pull to one side, it's likely that on e front hub is enga ged. If both hubs are engaged, steering effort increases bu t remains balance[...]

38 OPERA TION Failure to operate the A T V properly can re sult in a coll ision, 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 fo r your new Polaris A TV is the first ten hours[...]

39 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 66. Add oil if neces- sary to maintain the level in the safe operating range. 3. Drive slowly at first. Select an op en area t hat[...]

40 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 o ne under 16 year s of age to operate this vehicle . Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicle. 3. Never carry a passenger on this A TV . 4. Engine ex haus[...]

41 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 rid ing club or local officials. Help keep[...]

42 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 73 Brake fluid Ensure pr[...]

43 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 brake. 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. Si[...]

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

45 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit uprigh t with both feet on the footrests and both 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 determine your path of travel. 6. Release the parking brake. 7. Slowl[...]

46 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 sl ightly . T o turn, steer in the direction of the turn,[...]

47 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 precaution s: 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 t o lose traction. NOTICE: Se[...]

48 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[...]

49 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure 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. S[...]

50 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[...]

51 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 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 hi cle, or on the lef[...]

52 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 v oid operating th[...]

53 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 s lowly and use ex tra cau tion when operating on unfamil[...]

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

55 OPERA TION Parking on an Incline A void parking on an incline if po ss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock th e parking brake. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve off.[...]

56 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[...]

57 OPERA TION Hauling Cargo Never exceed the weight capacities specified for your A T V on warning labels and in the specifications section of this manual. Carg o weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce s peed and car go w[...]

58 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 a rrestor that was tested and qual[...]

59 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 intenance chart . Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

60 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[...]

61 MAINTENANCE Periodic Maintenance Chart Perform all services at whiche ver main tenance inter val is r eac hed first. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q Steering - Pre- Ride - Make adjustments as need ed. See Pre-Ride Checklist on page 42. X F ront suspension - Pre- Ride - X Rear su spension - Pr[...]

62 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) X General lubrication 50 H 3 M 500 (800) Lubricate all fitti[...]

63 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Exhaust muffler/ pipe 100 H 12 M 1000 (1600) Inspect Q E Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed Q E Ignition Timing 100 H 12 M 1000 (1600) Inspect X Wiring 100 H 12 M 1000 (1600) Inspect for wear , rout[...]

64 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 59. Items not listed in the chart should be lubric ated at the Ge neral Lubrication interval. See page 1 1 1 for the part numb ers of Polaris products. The a-arms and lower control arms are lubricated a[...]

65 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)[...]

66 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 -5 0 oil. Follow the manufacturer's re commendatio ns for ambient tempera- ture operatio[...]

67 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 59. 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. [...]

68 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[...]

69 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[...]

70 MAINTENANCE T r ansmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 59. Maintain the oil level at the bottom of the fill hole threads. See page 1 1 1 for the part numbers of Polaris products. The fill plug is located on the left si de of the A TV , under the r[...]

71 MAINTENANCE T r ansmission 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 pro[...]

72 MAINTENANCE Front Gearcase Fluid Always check and change the front gearcase fluid at the intervals out- lined in the Periodic Maintenance Ch art beginnin g on page 59. Maintain the fluid level at the bottom of the f ill hole threads. See page 1 1 1 for the part numbers o f Polaris products. Front Gearcase Fluid Recommendations Fluid Check 1. Pos[...]

73 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[...]

74 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 to e alignment and adjustment. Do not attemp t to adjust ti e rod alignment. All tie rod adjustments should be perf[...]

75 MAINTENANCE S teering Assembly The steering assemb ly of the A TV should be checked period ically for loose nuts and bo lts. If loose nuts and bolts are found, see yo ur Polaris dealer for service before ope rating the vehi cle. Camber and Caster The camber and caster are non-adjustable. Rear S pring The rear shock absorber spring is adjusted by[...]

76 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. W ARNING! Improper adjustme nt of the handleba rs or inco rrect torquing 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[...]

77 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr operly inflated tires, no n-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[...]

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

79 MAINTENANCE Ti r e s Wheel Nut T orque S pecifications 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)[...]

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 remove 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 , t[...]

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 cloggin g. Replace if needed. 3. Check the hoses for cracks , deterioration, [...]

82 MAINTENANCE Carburetor Y our Polaris A TV is calibrated at the fa ctory 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 [...]

83 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 [...]

84 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 - 10 mm) deflection. N[...]

85 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. l b s. (61 Nm) for machines with a hitch.[...]

86 MAINTENANCE Cooling System The engin e coolant level is controll ed, or maintained, 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[...]

87 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[...]

88 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 brake . 4. Measure [...]

89 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 promptly . Always make sure lights are adjusted properly for best visibility . Headlamp Replacement When servicing a ha logen lamp, don't[...]

90 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 [...]

91 MAINTENANCE Spar k P l ug s S p ark Plug Recommendatio ns Refer to the specifications section begi nning on page 1 16 for the recom- mended spark plug type and gap for 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[...]

92 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[...]

93 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[...]

94 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 materials from the are a. Wear eye pr otection and leather work gloves. Do not stand behind or in front of the vehicle wh ile purging. [...]

95 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[...]

96 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[...]

97 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. Allo w the water to drain completely . Reinstall the dra in plug. 3. S tart the engine. Plac[...]

98 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 , alw ays 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 [...]

99 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock th e 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. L[...]

100 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully charged 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 102 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the ba ttery in[...]

101 MAINTENANCE Battery Batter y Stor 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[...]

102 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent dama ge from leak- ing or spilled ele ctrolyte during cha r g ing. See pa ge 99. 2. Char ge the battery with a charging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1[...]

103 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%-[...]

104 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 components. 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, inc[...]

105 MAINTENANCE Cleaning and S torage W ashing th e 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 [...]

106 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[...]

107 MAINTENANCE Cleaning and S torage Sto r a g e Tips NOTICE: S tarting the engine during the storag e period 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 104. Stabilize t[...]

108 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 59. • Demand drive unit (front gearcase) • T ransmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test st[...]

109 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 59. Battery Storage See pages 101-102 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV[...]

110 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 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 A TV to th[...]

111 POL ARIS PRODUCTS P art # Descrip tion Engine L ubricant 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 Lubrica nt s 2873602 Premium AGL Synthetic Gearcase Lubrica nt (qt./.95 l) 2873603 P[...]

112 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 51). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or u s e low range (if equipped) more frequently . Insufficient warm-up at low ambien t tempera- tur[...]

113 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 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 [...]

114 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St 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 Soluti[...]

115 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[...]

116 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 accessor ies) Dry W e ight 571 lbs. (259.5 kg) Fuel Capacity 3.5 gal. (13.2 l) Engine Oil Capacity 2 qts. ( 1.9 l) T ransmission Oil 32 oz. (946 ml) Front Gearcase Fl uid 4 oz. (120 ml) Coolan[...]

117 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, Fron t 2:1 Drive Ratio, Final 2.77:1 Drive Chain 520 O-Ring T ires/Pressure, Front 23 x 7-10 (4 psi/27.6 [...]

118 W A RRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, 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[...]

119 W ARRANTY W ARRANTY COVERAGE AND E XCLUSIONS: LIMIT A T IONS OF W ARRANT IES AND REMEDIE S The Polaris l imited warranty excludes any failu res that are not caused by a defect 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[...]

120 W A RRANTY 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 SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DI SCLAIMS ALL EXP RESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY . Some states do not allow limi- tations on[...]

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 LOCA- TION. This policy does not apply to vehicles that have receiv ed authorization for export from Polaris Industries. Deal[...]

122 W A RRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally pur chased, a ll warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you ha[...]

123 W ARRANTY U.S.A. EP A Emis sion s Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limit ed warranty is in addition to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with th[...]

124 MAINTENANCE LOG Present this section of your manual 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[...]

125 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

126 INDEX A Air Filt er . . . . . . . . . . . . . . . . . . . . . 80 All Wh eel Drive Swit ch. . . . . . . . . . 27 All Wheel Drive Syst em . . . . . . . 36-37 AWD Switch . . . . . . . . . . . . . . . . . . 36 AWD System . . . . . . . . . . . . . . . . 36-37 B Battery . . . . . . . . . . . . . . . . . . . 98-103 Charging (Conventional) . . . . 102 [...]

127 INDEX H Handlebar Adjust ment . . . . . . . . . . . 76 Hauling Cargo . . . . . . . . . . . . . . . 56-57 Headlamp Replaceme nt . . . . . . . . . . 89 Headlight Be am Adjustment . . . . . . . 88 Headlight S witch . . . . . . . . . . . . . . . . 27 Helmet . . . . . . . . . . . . . . . . . . . . . . . . . 8 I Idle RPM Adjus tment . . . . . . . . .[...]

128 INDEX T Throttle Cable Freeplay . . . . . . . . . . 75 Throttle Lever . . . . . . . . . . . . . . . . . 28 Tire Tread Depth . . . . . . . . . . . . . . . 77 Tires . . . . . . . . . . . . . . . . . . . . . . 77-79 Front Wheel Hub Tightening . . 77 Tread Depth . . . . . . . . . . . . . . . 77 Wheel Install ation . . . . . . . . . . 78 Wheel Nu t [...]