Polaris Scrambler 500 4x4 Owner's Manual
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Polaris Scrambler 500 4x4 Owner's Manual

Polaris Scrambler 500 4x4 Owner's Manual

Polaris 2004 atv owner's manual
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  • Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
  • Page 4 We’ve created a Web site just for you! Check it out... www.polarisindustries.com/owner Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out...
  • Page 5 Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 6: Welcome

    S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...

  • Page 8: Table Of Contents

    EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION SPECIFICATIONS POLARIS PRODUCTS TROUBLESHOOTING WARRANTY ......

  • Page 9: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced.

  • Page 10: Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 11: Operator Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your ATV or in this manual, alerts you to the potential for personal injury.
  • Page 12 S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
  • Page 13 SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

  • Page 14: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 15 ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. WARNING WARNING...
  • Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 17 SAFETY Operator Safety POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.
  • Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads.
  • Page 19 SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
  • Page 20 Operator Safety POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
  • Page 21 SAFETY Operator Safety POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING...
  • Page 22 Operator Safety POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition.
  • Page 23 SAFETY Operator Safety POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 24 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.
  • Page 25 SAFETY Operator Safety POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds.
  • Page 26 SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill.
  • Page 27 SAFETY Operator Safety POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill.
  • Page 28 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.
  • Page 29 SAFETY Operator Safety POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
  • Page 30 Operator Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
  • Page 31 SAFETY Operator Safety POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
  • Page 32 Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.
  • Page 33 SAFETY Operator Safety POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.
  • Page 34 Operator Safety Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

  • Page 35: Fuel Safety

    SAFETY Fuel Safety Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gaso- line. 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 is performed or where gasoline is stored.
  • Page 36 ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
  • Page 37 SAFETY Safety Decals and Locations WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE AN APPROVED ON PUBLIC HELMET AND ROADS PROTECTIVE GEAR NEVER operate: ALWAYS: NEVER CARRY NEVER USE PASSENGERS WITH DRUGS OR ALCOHOL WARNING 7077920...
  • Page 38 To 40 Ft. Lbs. (For models with a hitch). 7078572 MANUFACTURED BY: POLARIS IND. INC. DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ...
  • Page 39 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

  • Page 40: Override Switch

    Electrical Switches Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Override Switch (1) (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system.

  • Page 41: Indicator Lights

    FEATURES AND CONTROLS Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
  • Page 42 Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

  • Page 43: Brake Lever

    FEATURES AND CONTROLS Brake Lever Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar.
  • Page 44 If the fluid level is low add DOT 3 brake fluid only. DO NOT OVERFILL. See page 117 for the part numbers of Polaris products. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.

  • Page 45: Parking Brake

    FEATURES AND CONTROLS Parking Brake Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1.

  • Page 46: Auxiliary Brake

    Auxiliary Brake Aggressively applying the auxiliary rear brake when backing downhill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

  • Page 47: Fuel Valve

    FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 51 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle, below the fender.
  • Page 48 Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. F: Forward N: Neutral R: Reverse Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.
  • Page 49 The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting.

  • Page 50: Engaging Wheel Hubs

    All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris exclusive, AWD system that’s activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times.

  • Page 51: Disengaging Wheel Hubs

    FEATURES AND CONTROLS All Wheel Drive (AWD) System Disengaging Wheel Hubs Although the hubs normally disengage when operating in reverse, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, it’s likely that one front hub is engaged . If both hubs are engaged, steering effort increases but remains balanced from left to right, and vehicle speed is somewhat restricted.

  • Page 52: Operation

    Break-In Period The break-in period for your new 4-cycle Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.
  • Page 53 OPERATION Pre-Ride Inspection If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your ATV is in proper working condition before each use.

  • Page 54: Starting The Engine

    Starting the Engine Starting a Cold Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. Operating the vehicle immediately after starting could cause engine damage.
  • Page 55 OPERATION Starting the Engine Starting a Cold Engine 3. Move the engine stop switch to RUN. NOTE: Do not press the throttle while starting the engine. 4. Turn 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 engine starts.
  • Page 56 Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. OPERATION...

  • Page 57: Hauling Cargo

    Accessory racks and hitches are available from your Polaris dealer. Always read and understand the load distribution warnings on all warning labels, and never exceed the specified weight capacities for the vehicle.
  • Page 58 Hauling Cargo Procedures and Precautions S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN HAULING CARGO. S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

  • Page 59: Driving Safely

    OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 60: Making Turns

    Driving Safely Making Turns Your Polaris ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

  • Page 61: Driving On Slippery Surfaces

    OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids.
  • Page 62 Driving Safely Sidehilling Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible.

  • Page 63: Driving Uphill

    OPERATION Driving Safely Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.
  • Page 64 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6.

  • Page 65: Driving Downhill

    OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single brake lever.

  • Page 66: Turning Around On A Hill

    Driving Safely Turning Around on a Hill Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.

  • Page 67: Driving Through Water

    OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2.

  • Page 68: Driving Over Obstacles

    Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 69: Driving In Reverse

    Use with caution. Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Most Polaris ATVs are equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed.

  • Page 70: Parking On An Incline

    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration.

  • Page 71: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 72: Periodic Maintenance Schedule

    Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Contact your Polaris dealer for more information. Polaris has a wide range of additional accessories available for your ATV. See your Polaris dealer. Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
  • Page 73 Perform all services at whichever reading is reached first. Improperly performing the procedures marked with a result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Brake System Auxiliary Brake...
  • Page 74 1000 mi. 100 hrs./ 6 months 1000 mi. 100 hrs. 6 months Check operation daily; ap- ply Polaris dielectric grease to socket when replaced Inspect; replace as needed Inspect level monthly; change annually Check terminals; clean Inspect; replace annually and as needed Inspect periodically Check monthly;...
  • Page 75 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Improperly performing the procedures marked with a result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Carburetor float bowl Throttle Cable/ETC Switch Choke (enricher)
  • Page 76 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Fuel system Fuel filter Radiator Cooling system hoses Front hubs (AWD) " Clutches (drive and driven) Engine mounts Valve clearance Brake fluid Spark arrestor Idle speed Recoil housing Toe adjustment Headlight aim More often under severe use, such as dirty or wet conditions "...

  • Page 77: Lubrication Recommendations

    More often under severe use, such as wet or dusty conditions " Polaris Premium All Season Grease or grease conforming to NLG No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long...
  • Page 78 MAINTENANCE AND LUBRICATION Lubrication Recommendations (10) 4 or 8 o’clock position- (end view)
  • Page 79 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Date Dealer or Person Remarks...
  • Page 80 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person...

  • Page 81: Premium 4 Synthetic Oil

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable as long as it’s 0W-40.

  • Page 82: Engine Oil Check

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check 1. Position the machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds, then stop the engine. 3. Remove the dipstick (1), which is located on the left side of the vehicle.

  • Page 83: Oil And Filter Change

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin. Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first.
  • Page 84 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 9. Place shop towels beneath the oil filter (1). Using an oil filter wrench, turn the filter counterclockwise to remove. 10. Using a clean, dry cloth, clean the filter sealing surface on the crankcase.
  • Page 85 Change transmission oil annually. We recommend the use of AGL Synthetic Gearcase Lubricant. See page 117 for the part numbers of Polaris products. 1. Position the ATV on a level surface and remove the fill plug (1),...

  • Page 86: Front Gearcase Oil Check

    1000 miles (1600 km), whichever comes first. Maintain the oil level at the bottom of the fill plug threads. Change the oil annually. We recommend the use of Polaris Angle Drive Fluid. See page 117 for the part numbers of Polaris products.

  • Page 87: Drive Chain

    Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm). Regularly lubricate the drive chain with Polaris Chain Lube, an SAE 80-90 lube or an approved o-ring chain spray lube. See page 117 for the part numbers of Polaris products.
  • Page 88 (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. WARNING...
  • Page 89 Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill. WARNING WARNING...
  • Page 90 MAINTENANCE AND LUBRICATION Adjustments Brakes 1. Check the brake system for fluid leaks. 2. Check the brakes for excessive travel or spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64″...

  • Page 91: Steering Assembly

    Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable.
  • Page 92 Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for rider preference.

  • Page 93: Carburetor Adjustments

    MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance 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 for each 1000-foot (304.8 m) increase in elevation.

  • Page 94: Wheel Removal

    MAINTENANCE AND LUBRICATION Adjustments Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in your owner’s manual.

  • Page 95: Wheel Installation

    5. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service.

  • Page 96: Front Wheel Hub Tightening

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less.

  • Page 97: Rear Drive Chain Slack

    MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components. Always make sure the slack is within the stated specifications. 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.
  • Page 98 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack 6. Roll the ATV forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1). 7. Tighten the eccentric locking bolts to 30 ft.

  • Page 99: Engine Cooling System

    50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 117 for the part numbers of Polaris products. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations...
  • Page 100 MAINTENANCE AND LUBRICATION Engine Cooling System Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair.

  • Page 101: Headlight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 102: Taillight/Brakelight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1) and replace it with a new lamp.

  • Page 103: Filter Systems

    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry.
  • Page 104 MAINTENANCE AND LUBRICATION Spark Plugs Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 114 Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.

  • Page 105: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
  • Page 106 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV. Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water.
  • Page 107 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the drive belt.
  • Page 108 Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation.
  • Page 109 MAINTENANCE AND LUBRICATION Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.

  • Page 110: Battery Removal

    MAINTENANCE AND LUBRICATION Battery Improperly connecting or disconnecting battery cables can result in an explosion 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.

  • Page 111: Battery Charging

    MAINTENANCE AND LUBRICATION Battery Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take the battery to your dealer for testing and recharging.
  • Page 112 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action (Using constant current charger @ standard amps...

  • Page 113: Cleaning And Storage

    Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

  • Page 114: Storage Tips

    It also prevents bacterial growth and promotes better starting after the storage period. 1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer. Follow the instructions on the container for the recommended amounts.

  • Page 115: Fluid Levels

    7. Treat the fuel system with Polaris Carbon Clean. 8. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline. Engine Anti-Freeze Test engine coolant strength and change if necessary.

  • Page 116: Transporting The Atv

    MAINTENANCE AND LUBRICATION Transporting the ATV Follow these procedures when transporting the vehicle. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly.

  • Page 117: Specifications

    SPECIFICATIONS 2004 Scrambler 500 4x4 Body Style Gross Vehicle Weight Fuel Transmission Oil Coolant Engine Oil Front Rack (Accessory) Rear Rack (Accessory) Hitch Towing Rating Hitch Tongue Weight Capacity Unbraked Trailer Towing Capacity* Turn Radius Ground Clearance Height Length Width...
  • Page 118 2004 Scrambler 500 4x4 Drive System Type Shift Type Gear Reduction - Reverse Gear Reduction - Forward Front Drive (ratio) Final Drive (ratio) Drive Chain Front Tires Rear Tires Front Suspension: Mac Strut Rear Suspension: Progressive Rate Swing Arm Shock Adjustment...

  • Page 119: Jetting Chart

    SPECIFICATIONS 2004 Scrambler 500 4x4 Jetting Chart Altitude AMBIENT TEMPERATURE Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) Clutching Chart Altitude Meters 0-1800 (Feet) (0-6000) 1800 & above (6000 & above) Below 40° F (Below 5° C) 152.5 Shift Drive Clutch Weight...

  • Page 120: Polaris Products

    60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.) Additives / Miscellaneous 2872113 Disc Brake Quiet, Aerosol (9 oz.) 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870990 DOT3 Brake Fluid 2872893 Engine Degreaser 2871956 Loctitet 565 Thread Sealant POLARIS PRODUCTS...

  • Page 121: Troubleshooting

    TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in high range. Starting out going up a steep incline.
  • Page 122 Turn the fuel valve on Replace with new fuel Inspect plug(s), replace if necessary Inspect plug(s), verify stop switch is on Immediately see your Polaris dealer Inspect, clean and/or replace spark plugs Replace the filter Recharge battery to 12.8 VDC...
  • Page 123 Incorrect jetting Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...
  • Page 124 Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.8 VDC...

  • Page 125: Warranty

    WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.

  • Page 126: Engine Oil

    HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re- pair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 127 How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...

  • Page 128: Index

    Accessories ....Adjustments ....Age Restrictions ....Air Filter .
  • Page 129 Parking on an Incline ... Periodic Maintenance Schedule POLARIS PRODUCTS ..Pre-Ride Inspection ... . .

This manual is also suitable for:

Scrambler 500 4x4 2004

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