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Polaris Scrambler 500 2X4 International Owner's Manual

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  • Page 2

    FOLLOW ALL INSTRUCTIONS AND WARNINGS. Pantone 425 C NEVER CARRY NEVER USE PASSENGERS WITH DRUGS OR ALCOHOL For your nearest Polaris dealer, visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A. Part No. 9922077 Rev 02 Printed in U.S.A.

  • Page 3

    WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • Quadricycles • RANGER utility vehicles •...

  • Page 4

    POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 5: Table Of Contents

    Specifications ......102 Polaris Products..... . . 104 Troubleshooting .

  • Page 6: Introduction

    The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

  • Page 7

    WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

  • Page 8: Vehicle Identification Numbers

    INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. The ignition switch must be replaced if all keys are lost. #### Key Number Vehicle Model Number: ___________________________________________________ Frame VIN: ____________________________________________________________ Engine Serial Number: ___________________________________________________...

  • Page 9: Safety

    You were also provided with printed materials that explain safe operating procedures. Review this informa- tion on a regular basis. If you purchased your vehicle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer. Equipment Modifications...

  • Page 10

    SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Eye Protection Long Helmet Sleeves Gloves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 11: Eye Protection

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever 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 12: Operator Safety

    Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com. Never permit others to operate this vehicle unless...

  • Page 13

    Operator Safety Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • 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 14

    SAFETY Operator Safety Never consume alcohol or drugs before or while operating this vehicle. Keep both hands on the handlebars. Keep both feet on the footrests. Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation.

  • Page 15

    SAFETY Operator Safety Never carry a passenger on the rear rack. Ejection from the vehicle or contact with moving components can result in serious injury or death. Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control, accident and/or injury. Avoid sudden turns or swift movement of the handlebars.

  • Page 16

    SAFETY Operator Safety Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn. See page 37. Never attempt jumps or other stunts. Always follow the procedures outlined in this manual for driving through water.

  • Page 17

    SAFETY Operator Safety Always follow the procedures outlined in this manual for driving on hills. See page 39. Never operate on hills too steep for this vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°.

  • Page 18

    SAFETY Operator Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Always travel slowly when operating on unfamiliar terrain. Use extra caution. Always follow the procedures outlined in this manual for driving in reverse. See page 45.

  • Page 19

    Allow a greater distance for braking. If this vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

  • Page 20: General Warning

    If an informational or graphic label becomes illegible or comes off, con- tact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label. General Warning...

  • Page 21: Discretionary Warning

    Safety Labels and Locations Discretionary Warning Discretionary Warning WARNING • Never operate this ATV on HILLS steeper than 25 degrees vent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. Steering becomes difficult.

  • Page 22: No Passenger" Warning

    Safety Labels and Locations “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.

  • Page 23: Age 16 Warning

    Safety Labels and Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. Clutch Cover Warning WARNING •...

  • Page 24: Features And Controls

    FEATURES AND CONTROLS Switches Headlight Switch Engine Stop Switch Override Switch Main Key Switch Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and press the override switch. WARNING! Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death.

  • Page 25: Headlight Switch

    FEATURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lights on and off and to change 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.

  • Page 26

    FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.

  • Page 27: Brake Lever

    FEATURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding.

  • Page 28: Parking Brake

    FEATURES AND CONTROLS Parking Brake 1. Place the transmission in gear. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5.

  • Page 29

    FEATURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxiliary rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.

  • Page 30: Fuel Valve

    FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 34 for correct choke and throttle settings during start- ing. Fuel Tank Cap Fuel Tank Always refuel with the engine stopped, and outdoors or in a well ventilated area.

  • Page 31: Transmission Gear Selector

    Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. F: Forward Gear N: Neutral R: Reverse To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause...

  • Page 32: Operation

    Break-In Period The break-in period for your new Polaris vehicle 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 proce- dures for a proper break-in.

  • Page 33

    Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 28. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 56. Add oil as needed to maintain the level in the proper range. 3.

  • Page 34: Safe Operation Practices

    OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle.

  • Page 35: Pre-ride Checklist

    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 approved helmet, goggles, and...

  • Page 36: Starting The Engine

    OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Place the transmission in neutral. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.

  • Page 37

    Starting the Engine 9. 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. NOTICE: Operating the vehicle immediately after starting could cause engine damage.

  • Page 38

    OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 2. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 3. Squeeze the brake lever. 4. Start the engine and allow it to warm up. 5.

  • Page 39: Turning The Vehicle

    OPERATION Turning the Vehicle To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. The same leaning technique should be used for turning in reverse. Practice making turns at slow speeds before attempting to turn at faster speeds.

  • Page 40: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3.

  • Page 41: Driving Uphill

    Driving Uphill Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25° maximum). 3.

  • Page 42

    OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.

  • Page 43: Driving Downhill

    Driving Downhill When driving downhill, follow these precautions: 1. Avoid steep hills (25° maximum). 2. Avoid hills with excessively slippery or loose surfaces. 3. Shift body weight uphill. 4. Drive straight downhill. 5. Slow down. Never go down a hill at high speed. 6.

  • Page 44

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

  • Page 45: Driving Through Water

    Driving Through Water Your Polaris vehicle can operate through water with a maximum recom- mended depth equal to the bottom of the footrests. Follow these proce- dures when operating through water: 1. Determine water depths and current before entering water.

  • Page 46: Driving Over Obstacles

    OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Be alert. Watch the terrain. Use extra caution 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches.

  • Page 47: Driving In Reverse

    Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6.

  • Page 48: Hauling Cargo

    OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 49: Load Distribution

    Hauling Cargo Load Distribution Accessory racks and hitches are available from your Polaris dealer. Read and understand the load distribu- tion warnings listed on the vehicle warning labels. Never exceed the specified weights. Cargo weight should be evenly distributed (1/3 on the...

  • Page 50: Parking On An Incline

    OPERATION Parking on an Incline Avoid parking on an incline. If it's unavoidable, follow these precau- tions: 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5.

  • Page 51: 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 52: 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 111.

  • Page 53: Maintenance Chart Key

    Improperly performing the procedures marked with a component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use.

  • Page 54

    (if equipped) Transmission oil Engine breather filter (if equipped) 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) Pre-Ride Pre-Ride Pre-Ride Pre-Ride...

  • Page 55

    Periodic Maintenance Chart Item Hours Calendar Engine oil change (break-in) General lubrication Carburetor float bowl Throttle Cable/ ETC Switch Choke cable E Carburetor air intake ducts/flange Drive belt Cooling system Engine oil change Oil filter change Oil tank vent hose Valve clearance Fuel system/filter Radiator...

  • Page 56

    Spark arrestor E 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...

  • Page 57: Lubrication Guide

    Swing Arm Bushings Axle Housing Tie Rod Ends Lube PS-4 PLUS Performance Synthetic 2W-50 DOT 4 Only O-ring chain lube or SAE 80/90 Polaris AGL Synthetic Gearcase Lube Premium All Season Grease Premium All Season Grease Housing Tie Rod Ends...

  • Page 58: Engine Oil

    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 Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient tempera- ture operation.

  • Page 59: Oil And Filter Change

    Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine.

  • Page 60

    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.

  • Page 61: Oil Pump Priming

    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 approximately two inches (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure...

  • Page 62: Transmission Oil

    Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Maintain the oil level within the SAFE operating range on the dipstick. Transmission Oil Recommendations Gearcase Transmission Premium AGL Synthetic Gearcase Lubricant Oil Check 1.

  • Page 63: Oil Change

    Transmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan beneath the transmission oil drain plug area. 3. Loosen the jam nut. 4. Turn the adjuster bolt in to allow the removal of the drain plug. 5.

  • Page 64: Brake Fluid

    Always maintain brake fluid at the recommended level. Do not overfill. If the fluid level is low add DOT 4 brake fluid only. See page 104 for the part numbers of Polaris products. Under normal operation, the diaphragm extends into the reservoir as fluid level drops.

  • Page 65: Brake Fluid (auxiliary Foot Brake)

    Brakes Brake Fluid (Hand Brake) Check the brake fluid level in the master cylinder before each use of the vehicle. The master cylinder is located on the left handlebar. Maintain the fluid level 1/4" (6 mm) below the top edge of the master cylinder.

  • Page 66: Brake Check

    Brakes Brake Check Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily during normal opera- tion. 1. Always keep foot brake fluid at an adequate level. Check the foot brake system regularly for fluid leaks.

  • Page 67: Toe Alignment

    6. Measure the distance between the marks and record the measurement (2). 7. Subtract measurement 2 from measurement 1. The difference is the vehicle toe-out alignment. 8. If you discover improper alignment, see your Polaris dealer for ser- vice. MAINTENANCE...

  • Page 68: Rear Suspension

    MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Rear Suspension The rear suspension spring preload and...

  • Page 69: Throttle Cable Freeplay

    Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Slide the boots off the inline cable adjuster sleeve. Loosen the adjuster locknut. 2. Turn the adjuster until 1.6-3 mm of freeplay exists at the lever. Move the throttle lever back and forth several times while adjusting.

  • Page 70

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference.

  • Page 71

    Carburetor Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher. Above 1800 meters the engine air/fuel mixture becomes too rich and the engine loses approximately 3% of its power for each 300 meter increase in elevation.

  • Page 72: Drive Chain

    Maintain the stone guard to rear sprocket clearance at 1/8” (3 mm). Regularly lubricate the drive chain with Polaris Chain Lube, an SAE 80- 90 lube or an approved o-ring chain spray lube. See page 104 for the part numbers of Polaris products.

  • Page 73: Rear Drive Chain Slack

    Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three positions. At this point the chain should have 3/16"-3/8"...

  • Page 74

    Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or back- ward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position. 7. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch and 45 ft.

  • Page 75: Cooling System

    Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 104 for the part numbers of Polaris products.

  • Page 76: Radiator Coolant

    Radiator Coolant To ensure that the coolant maintains 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 cooling system has been drained for maintenance or repair.

  • Page 77: Headlamp Replacement

    Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Headlamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers.

  • Page 78: Indicator Lamp Replacement

    MAINTENANCE Lights Taillight/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.

  • Page 79: Wheel And Hub Tightening

    MAINTENANCE Tires 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. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

  • Page 80: Wheel Removal

    MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Safely place jackstands under the vehicle. 4. Remove the wheel nuts. Remove the wheel.

  • Page 81: Wheel Nut Torque Specifications

    Tires Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loos- ened for service. Item Front Wheel Nuts Rear Wheel Nuts Front 27 ft. lbs. (37 Nm) Torque Specification 27 ft. lbs. (37 Nm) 50 ft. lbs. (68 Nm) MAINTENANCE Rear 50 ft.

  • Page 82: Air Filter

    Air Filter 1. Position the vehicle on a level surface. Place the transmission 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.

  • Page 83: Breather Filter

    Breather Filter 1. Remove the clamps and pull the breather filter out of the hoses. It's not necessary to remove the lower hose from the engine. 2. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging.

  • Page 84: Spark Plugs

    Refer to the specifications section beginning on page 102 for the recom- mended spark plug type and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Plug Condition New Spark Plug...

  • Page 85: Spark Plug Condition

    MAINTENANCE Spark Plugs Spark Plug Condition Normal Spark 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 indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and white.

  • Page 86: Vehicle Immersion

    Vehicle Immersion If the vehicle stops while fully submerged, 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 vehicle to a dealer before starting it, fol- low the steps outlined below.

  • Page 87: Spark Arrestor

    Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves.

  • Page 88: Pvt System

    • 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 89

    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 90: Pvt Drying

    MAINTENANCE PVT System PVT Drying There may be some instances when water 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. Allow the water to drain completely. Reinstall the drain plug.

  • Page 91

    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. WARNING Battery electrolyte is poisonous.

  • Page 92: Battery Removal

    MAINTENANCE Battery Battery Removal 1. Place the transmission in gear. 2. Lock the parking brake. 3. Disconnect the battery hold-down strap. 4. Remove the battery cover. 5. On conventional batteries, remove the battery vent tube. 6. Disconnect the black (negative) battery cable first. 7.

  • Page 93: Battery Installation

    Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 93 before installing the battery.

  • Page 94: Battery Storage

    Tip: Power plug leads may need to be bent down so that the battery cover can be installed. Polaris recommends maintaining battery charge by using a Polaris Bat- tery Tender charger or by charging about once a month to make up for normal self-discharge.

  • Page 95

    Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 90. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.

  • Page 96

    MAINTENANCE Battery Battery Charging (Sealed Battery) 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 charger @ standard amps specified on top of battery)

  • Page 97: Cleaning And Storage

    Do not allow these types of products to contact 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. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

  • Page 98: Polishing 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 • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

  • Page 99

    Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 100: Storage Tips

    95. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

  • Page 101

    7. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.

  • Page 102

    Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 50. Battery Storage See page 92-94 for storage and charging procedures. Storage Area/Covers 1.

  • Page 103: Transporting The Vehicle

    Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Turn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6.

  • Page 104: Specifications

    Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Coolant Front Rack Capacity (Accessory) Rear Rack Capacity (Accessory) Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication...

  • Page 105: Jetting Chart

    Weight 0-1800 (0-6000) 5630710 1800 & above (6000 & above) 5630709 Scrambler 500 2X4 PVT (Polaris Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 12/36 76P 520 O-Ring 23 x 7-10 (4 psi/27.6 kPa) 22 x 12-10 (3 psi/20.7 kPa) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 10.5"...

  • Page 106: Polaris Products

    2871326 Carbon Clean Plus (12 oz./355 ml) 2870652 Fuel Stabilizer (16 oz./.47 l) 2872189 DOT4 Brake Fluid (12 oz./355 ml) 2871956 Loctite 2859044 Polaris Battery Tender Engine Lubricant Coolant Grease / Specialized Lubricants Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 107: Troubleshooting

    Dry out the PVT. See page 88. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank, fuel lines or carburetor. See your dealer.

  • Page 108

    Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Inspect, clean and/or replace spark plugs Replace the filter Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark plugs...

  • Page 109

    Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Idle set too low Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...

  • Page 110

    Set gap to specs or replace plug Check all connections and tighten Recharge the battery to 12.8 VDC Replace with fresh recommended fuel Inspect and clean or replace See your dealer See your dealer See your dealer Clean engine exterior; see your Polaris dealer...

  • Page 111: Warranty

    LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material 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 112

    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 113: Maintenance Log

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 114

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 115: Index

    Air Filter ..... . 80 Battery ....89-94 Charging (Conventional) .

  • Page 116

    Periodic Maintenance Chart ..50-54 Polaris Product List ... . . 104 Polishing the Vehicle... . . 96 Pre-Ride Checklist.

  • Page 117

    Throttle Cable Freeplay ..67 Throttle Lever ....24 Tires ..... . 77-79 Tread Depth .

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