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Polaris Scrambler 9921620 Owner's Manual

Quadricycle
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Summary of Contents for Polaris Scrambler 9921620

  • Page 3 S Quadricycles S RANGER utility vehicles S Victory motorcycles 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 4 Copyright 2007 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 5: Table Of Contents

    Maintenance ......Specifications Polaris Products Troubleshooting Warranty ....... .

  • Page 7: Know Your Vehicle

    Record your vehicle’s identification 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 your key number) and mating it with one of your existing keys.

  • Page 8: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. 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 vehicle or in this manual, alerts you to the potential for personal injury.

  • Page 9: Safety Training

    WARNING Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris Quadricycle 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...

  • Page 10: Operator Safety

    S Never operate a Quadricycle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com. S Never allow anyone under 16 years of age to operate this Quadri- cycle.
  • Page 11 Operator Safety S Always have the Quadricycle inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the Quadricycle or for your abili- ties. Practice on smaller hills before attempting larger hills.
  • Page 12 S Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT QUADRICYCLE SAFETY, contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com.
  • Page 13 HOW TO AVOID THE HAZARD Never operate a Quadricycle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this Quadricycle.
  • Page 14 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on a Quadricycle. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the Quadricycle, which could cause an accident and injury to the operator and/or passenger.
  • Page 15 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this Quadricycle without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating a Quadricycle without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
  • Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the Quadricycle 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 a Quadricycle could result in an accident causing severe injury or death.
  • Page 17 SAFETY Operator Safety WARNING 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 POTENTIAL HAZARD Failure to inspect the Quadricycle before operating.
  • Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the Quadricycle.
  • Page 19 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 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the Quadricycle or for your abilities. Never operate the Quadricycle on hills steeper than 25_.
  • Page 21 SAFETY Operator Safety WARNING 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 22 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 Quadricycle around on any hill until you’ve mastered the turning technique (on level ground) as described in the...
  • Page 23 SAFETY Operator Safety WARNING 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 24 SAFETY Operator Safety WARNING 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 25 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the Quadricycle 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 Quadricycle through deep or fast-flowing water.
  • Page 26 Never modify the Quadricycle 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 Quadricycle and should be installed and used according to approved instructions. See your authorized Polaris Quadricycle dealer for more information.
  • Page 27 SAFETY Operator Safety WARNING 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. WARNING 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 28: Fuel Safety

    SAFETY Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 29: Safety Decals And Locations

    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. The part number is printed on the decal.
  • Page 30 S use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns S avoid paved surfaces -- pavement may seriously affect handling and control LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.
  • Page 31 SAFETY Safety Decals and Locations No Passenger Warning (4) WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Age 16 Warning (5) WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.

  • Page 32: Safe Riding Gear

    2. Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V- -8, Z87.1, or CE.

  • Page 33: Features And Controls

    Electrical Switches WARNING 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 34: Indicator Lights

    FEATURES AND CONTROLS Light Switches The light switch is located on the left handlebar (1). It’s used to turn the lights on and off and to switch the lights from high beam to low beam. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switch is in the RUN position.

  • Page 35: Throttle Lever

    This vehicle 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 36: Brake Lever

    FEATURES AND CONTROLS Brake Lever WARNING Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever. The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar.
  • Page 37 If the fluid level is low add DOT 4 brake fluid only. DO NOT OVERFILL. See page 111 for the part numbers of Polaris products. WARNING Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.

  • Page 38: Parking Brake

    FEATURES AND CONTROLS Parking Brake WARNING Operating the vehicle 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. Locking the Parking Brake 1.

  • Page 39: Auxiliary Brake

    Auxiliary Brake WARNING Aggressively applying the 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 40: Fuel Valve

    FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 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 41 Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. F: Forward N: Neutral R: Reverse CAUTION 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 42: Recoil Starter

    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 43: Operation

    Break-In Period The break-in period for your new Polaris Quadricycle is 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 44 Ensure proper operation Check condition / slack, lubricate as needed Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear helmet, goggles, protective...

  • Page 45: Starting The Engine

    Starting the Engine WARNING 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. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral.
  • Page 46 OPERATION Starting the Engine 7. Move the engine stop switch to RUN. NOTE: Do not press the throttle while starting the engine. 8. 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 47: Driving Safely

    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 48: Hauling Cargo

    OPERATION Driving Safely 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. Maximum Towing Capacities Refer to the specifications at the rear of this manual for towing capacities.
  • Page 49 Driving Safely Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN HAULING CARGO.

  • Page 50: Making Turns

    Driving Safely Making Turns Your Polaris vehicle 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 51: Driving On Slippery Surfaces

    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 52 OPERATION Driving Safely Sidehilling WARNING 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 53: Driving Uphill

    Driving Safely Driving Uphill WARNING 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 54 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 55: Driving Downhill

    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 56: Turning Around On A Hill

    OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8’ (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2.

  • Page 57: Driving Through Water

    Driving Safely Driving Through Water Your vehicle 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. Choose a crossing where both banks have gradual inclines.

  • Page 58: Driving Over Obstacles

    OPERATION 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. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 59: Driving In Reverse

    Avoid backing on inclines, and avoid turning at sharp angles. NOTE: This Polaris vehicle is 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.
  • Page 60 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. Lock the parking brake. 3. Always block the rear wheels on the downhill side. See illustration.

  • Page 61: Emission Control Systems

    The engine and related components must be maintained at Polaris specifications to achieve optimal performance. Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.

  • Page 62: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 118.

  • Page 63: Periodic Maintenance Chart

    Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a result in component failure and lead to serious injury or death.
  • Page 64 MAINTENANCE Periodic Maintenance Chart Item Hours Calendar Brake pad wear " Battery Front gearcase oil " (if applicable) Transmission oil " Engine breather " filter (if equipped) General " lubrication Carburetor float bowl Throttle Cable/ ETC Switch Choke cable Carburetor air intake ducts/ flange Drive belt...
  • Page 65 Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 12 M 1000 (1600) Inspect for leaks...

  • Page 66: 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 67 MAINTENANCE Lubrication Recommendations...

  • Page 68: Engine Oil

    Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer’s recommendations for ambient temperature operation.

  • Page 69: Oil And Filter Change

    Engine Oil Oil and Filter Change CAUTION Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin. 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.
  • Page 70 MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 10. Lubricate the gasket on the new filter with a film of new engine oil.
  • Page 71 Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line (1) approximately 2I from the oil tank (2), between the end of the oil tank vent fitting and the vent...

  • Page 72: Transmission Oil

    Periodic Maintenance Chart beginning on page 60. Maintain the oil level within the SAFE operating range on the dipstick. We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 111 for the part numbers of Polaris products. Oil Check The transmission oil dipstick (1) is located on the right side of the vehicle.

  • Page 73: Oil Change

    Transmission Oil Refer to the specifications section beginning on page 108 for transmission oil capacity. 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 (A). 4.

  • Page 74: 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 111 for the part numbers of Polaris products.

  • Page 75: Toe Alignment

    Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle.
  • Page 76 Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 4 brake fluid. Do not overfill.
  • Page 77 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 78: Throttle Cable Freeplay

    MAINTENANCE Steering Assembly The steering assembly of the vehicle 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 79 Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference.
  • Page 80 MAINTENANCE Carburetor IMPORTANT: Your Polaris vehicle 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 81: Wheel Removal

    Wheels WARNING Operating your vehicle 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 vehicle and in your owner’s manual.

  • Page 82: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.

  • Page 83: 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 84: Rear Drive Chain Slack

    MAINTENANCE Rear Drive Chain Slack CAUTION Adjusting or operating the vehicle 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 85 Rear Drive Chain Slack 6. Roll the vehicle 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. lbs. (41 Nm) for machines without the hitch and 45 ft.

  • Page 86: Engine Cooling System

    50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 111 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 87: Radiator Coolant Level

    Engine Cooling System WARNING 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 88: Headlight Lamp Replacement

    MAINTENANCE 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 89: Indicator Lamp Replacement

    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). 3.

  • Page 90: Filter Systems

    MAINTENANCE 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 91: Spark Plugs

    Spark Plug Recommendations CAUTION 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 108 Refer to the specifications section beginning on page 108 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

  • Page 92: Recoil Housing

    MAINTENANCE Spark Plugs Spark Plug Inspection Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.

  • Page 93: Vehicle Immersion

    Vehicle Immersion CAUTION 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 Quadricycle to a dealer before starting it, follow the steps outlined below.

  • Page 94: Pvt System

    MAINTENANCE 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 95: Pvt Drying

    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 96: Spark Arrestor

    MAINTENANCE Spark Arrestor WARNING 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 97: Conventional Battery

    Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Battery Always keep battery terminals and connections free of corrosion.

  • Page 98: Battery Removal

    MAINTENANCE Battery WARNING 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. Battery Removal 1.

  • Page 99: Battery Installation

    Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on pages 99-101 before installing the battery. 1.

  • Page 100: Battery Storage

    Power plug leads may need to be bent down so that the battery cover can be installed. NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left...
  • Page 101 Battery Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks (1). Add only distilled water. Tap water contains minerals that are harmful to a battery.
  • Page 102 MAINTENANCE Battery Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 103 Battery Battery Charging (Sealed Battery) 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 MAINTENANCE Action charger @ standard amps...

  • Page 104: Cleaning And Storage

    Do not allow these types of products to come into contact with the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

  • Page 105: Washing The Vehicle

    Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips S Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 106 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a ”like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 107: Storage Tips

    Cleaning and Storage Storage Tips See page 111 for the part numbers of Polaris products. CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.
  • Page 108 7. Treat the fuel system with Polaris Carbon Clean. See page 105. 8. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.

  • Page 109: Transporting The Quadricycle

    Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 110: Specifications

    SPECIFICATIONS 2008 Scrambler 500 2X4 International Body Style Maximum Weight Capacity 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 Seat Height Dry Weight...
  • Page 111 2008 Scrambler 500 2X4 International Drive System Type Shift Type Gear Reduction - Reverse Gear Reduction - Forward Final Drive (ratio) Drive Chain Front Tires Rear Tires Front Suspension: Mac Strut Rear Suspension: Progressive Rate Swing Arm Shock Adjustment Front Brake Rear Brake Auxiliary Brake Parking Brake...

  • Page 112: Jetting Chart

    SPECIFICATIONS 2008 Scrambler 500 2X4 International 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 Spring 10WH...

  • Page 113: Polaris Products

    Coolant 2871323 60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.) Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid 2871956 LOCTITE 565 Thread Sealant 2871076 Polaris Battery Tendert Charger POLARIS PRODUCTS...

  • Page 114: 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 onto a pickup or tall trailer in high range Starting out going up a steep incline...
  • Page 115 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 116 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 117 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 118: Warranty

    LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in ma- terial or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any Quadricycle...
  • Page 119 HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris Quadricycles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

  • Page 120: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 121 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...

  • Page 123: Index

    Age Restrictions ....Air Filter ..... Auxiliary Brake .
  • Page 124 Parking on an Incline ... Periodic Maintenance Chart Polaris Products ....Pre Ride Inspection ... . .

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2008 scrambler 500 2x4 international

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