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Polaris 500 2X4 International Offroad Vehicle User Manual

Contents

1. and rear brakes These brakes gt 6 are hydraulically activated disc tvpe brakes that are activated KA by only one lever et Ile e H Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs A 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 Always contact your dealer for service before operating the vehicle Inspect and maintain the brake fluid level as outlined in this manual See page 63 25 FEATURES AND CONTROLS Parking Brake 1 Place the transmission in gear 2 Squeeze and release the brake lever two or three Et times then squeeze and H hold i ke c l IKA 3 Push the parking brake lock forward to engage the lock l eim f IQ 1r 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position A Operating the vehicle while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged b
2. Lubrication Dry sump Engine Cooling Liquid Displacement 499 cc Bore x Stroke 92 x 75 Alternator Output 250w 5000 rpm Compression Ratio 10 2 1 Carburetor BST 40 Pilot Jet 40 Main Jet 155 Needle Jet Y 0M 896 Jet Needle 6H25 94 3 Pilot Air Jet 160 Pilot Screw 2 0 turns Ignition System CDI Ignition Timing 30 2 5000 RPM Spark Plug Gap BKRGE 036 in 9 mm Based on EU Directive 76 432 EC 102 SPECIFICATIONS Scrambler 500 2X4 Driving System Type PVT Polaris Variable Transmission Shift Type Side Lever F N R Gear Reduction Reverse 3 05 1 Gear Reduction Forward 2 68 1 Drive Ratio Final 12 36 76P Drive Chain 520 O Ring Tires Pressure Front 23 x 7 10 4 psi 27 6 kPa Tires Pressure Rear 22 x 12 10 3 psi 20 7 kPa Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 10 5 26 7 cm travel Shock Adjustment Threaded Adjuster Brakes Front Fixed disc hydraulic floating caliper Brakes Rear Fixed disc hydraulic floating caliper Brake Auxiliary Fixed disc hydraulic floating caliper Brake Parking Hydraulic lock all wheel Headlight 2 Dual Beam 30w 30w Battery 12V 14AH Indicators High Beam High Temp Neutral Reverse Jetting Chart ALTITUDE Meters Feet AMBIENT TEMPERATURE
3. Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Engine oil change 25 1M 250 400 Perform a break in oil change E break in gt General 50 3M 500 800 Lubricate all fittings pivots lubrication cables etc Carburetor float 50 6M 500 800 Drain bowl periodically and bowl prior to storage E Throttle Cable 50 6M 500 800 Inspect adjust lubricate E JETC Switch replace if necessarv E j Choke cable 50 6M 500 800 Inspect adjust lubricate E replace if necessary E Carburetor air 50 6M 500 800 jInspect duct for proper seal intake ducts flange ing air leaks Drive belt 50 6M 500 800 Inspect adjust replace as needed Cooling system 50 6M 1000 1600 Inspect coolant strength seasonally pressure test system yearly gt Engine oil change 100 6M 1000 1600 JPerform a break in oil change E at 20 hours gt Oil filter change 100 6M 1000 1600 Replace with oil change E gt Oil tank vent hose 100 12M 1000 1600 Inspect routing condition E Valve clearance 100 12M 1000 1600 Inspect adjust E Fuel system filter 100 12M 1000 1600 Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years gt Radiator 100 12M 1000 1600 Inspect clean external surfaces gt Cooling hoses 100 12M 1000 1600 Inspect for leaks if applicable gt Engine mounts 100 12M 1000 1600 Inspect 53
4. Below 40 F 40 F and above Below 5 C 5 C and above 0 1800 0 6000 160 155 1800 3700 6000 12000 152 5 147 5 Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Spring Meters Feet Weight Spring Spring Setting 0 1800 10WH Blue Green Silver 40 0 6000 5630710 7041157 7041499 5131446 1 1 1800 amp above 10RH Blue Green Silver 40 6000 amp above 5630709 7041157 7041499 5131446 1 1 103 POLARIS PRODUCTS Part Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 95 1 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal 3 8 1 Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 l 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 l 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 0z 237 ml 2872277 Premium Demand Drive Hub Fluid 2 5 gal 9 5 I Coolant 2871323 2871534 60 40 Coolant gal 3 8 1 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 0z 89 ml 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Greas
5. 00 24 DAVES 5 655 sesso ia epee sta owas 71 79 Tread Depth 77 Wheel and Hub Tightening 77 Wheel Installation 78 Wheel Nut Torque 79 Wheel Removal 78 Toe Alignment 65 Towing Loads 47 Training 7 Transmission Oil 60 61 Transporting the Vehicle 101 Turning Around on a Hill 42 Turning the Vehicle 37 INDEX V Vehicle Identification Numbers 6 Vehicle Immersion 84 Ww Warning Symbols 4 Washing the Vehicle 95 96 Wheel and Hub Tightening 77 Wheel Installation 78 Wheel Nut Torque Specifications 79 Wheel Removal 78 115
6. Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 45 OPERATION Hauling Cargo A 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 NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity 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 Carrying loads on only one rack increases the possibility of ve
7. MAINTENANCE Periodic Maintenance Chart Headlight aim Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Exhaust muffler 100 12M 1000 1600 Inspect pipe E Spark plug 100 12M 1000 1600 Inspect replace as needed E Ignition Timing 100 12M 1000 1600 Inspect gt Wiring 100 12M 1000 1600 jInspect for wear routing security apply dielectric grease to connectors subjected to water mud etc E Clutches drive 100 12M 1000 1600 jInspect clean replace worn and driven parts E Front wheel 100 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200 24M 2000 3200 Change every two years Spark arrestor 300 36 M 3000 4800 Clean out E Idle speed Adjust as needed E Toe adjustment Inspect periodically adjust when parts are replaced Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 54 Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 50 Items not listed in the chart should be lubricated at the General Lubrication interval MAINTENANCE Item Lube Method Engine Oil PS 4 PLUS Performance See page 56 Synthetic 2W 50 Brake Fluid DOT 4 Only See page 63 Drive Chain s
8. Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gaso line with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Fuel Valve The fuel valve is located on the left side of the vehicle below the fender ON For normal operation OFF For vehicle storage OFF ON RES and when transporting RES Turn the valve to the reserve setting if the main fuel supply is exhausted Refuel as soon as possible Return the valve to the ON posi tion after refueling Reserve fuel range is about 7 10 miles 11 16 km Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 28 FEATURES AND CONTROLS 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 transmission damage Whenever the vehicle is left unattended always place the transmission in gear and lock the parking brake 29 OPERATION A Failure to operate the vehicle properly can result in a collis
9. O ring chain lube or SAE Lubricate 80 90 Transmission Oil Polaris AGL Synthetic See page 60 Gearcase Lube Swing Arm Bushings Axle Housing gt Premium All Season Grease Locate fittings on swing arm and grease with grease gun Tie Rod Ends gt Premium All Season Grease Lift boot clean away dirt and grease apply fresh grease by hand and reassemble Perform when suspension action becomes stiff or after washing Bushings 55 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS 4 PLUS Performance Syn thetic 2W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Specifications Lubricant Capacity Drain Plug Torque PS 4 PLUS Performance 2 ats 1 9 1 14 17 ft Ibs 19 23 Nm Synthetic 2W 50 4 Cycle Oil Oil Level The oil dipstick is located on the left side of the vehicle 1 Position the vehicle on a level surface Place the transmission in neutral Lock the parking brake 2 Start the engine Allow it to idle for 30 seconds Stop the engine 3 Remove the dipstick Wipe it dry with a
10. 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 If the recovery bottle has run dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the front panel to access the radiator pressure cap Remove the pressure cap 3 Ifcoolant is low use a fun nel and slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pres sure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 5 Secure the front panel 6 Fill the coolant recovery bottle to the upper mark on the bottle 7 Check the coolant level in the bottle frequently adding coolant as needed until the level stabilizes 74 MAINTENANCE 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 Oil from your skin leave
11. Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience 13 SAFETY Operator Safety A 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 A Never attempt jumps or other stunts A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 43 14 SAFETY Operator Safety A 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 Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 41 A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill See page 42 A Always follow the procedures outlined in this manual for crossing the side of a hill See page 40 Never attempt to turn this vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual 15 SAFETY Operator Safety A Always use the size and type of tires specified for your vehicle Maintain the proper ti
12. needed 3 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 4 Reinstall the filter and secure the clamps The filter is effective with the arrow pointing in either direction NOTICE Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for service 81 MAINTENANCE Spark Plugs Spark Plug Recommendations 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 Torque Specification New Spark Plug 12 15 Nm Previously Installed Spark Plug 23 27 Nm Spark Plug Inspection Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immedi ately check the spark plug for correct color See page 83 A A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the spark plug cap 2 Using the special wrench pro JA k vided in the tool pouch rotate E Tn the spark plug counterclock A wise to remove it 3 Inspect the electrodes for wear and carbon buildup Replace worn or fouled plugs Verify that the gap is at specification before installation 4 Reverse the
13. 1 2 turns into the tank threads Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank NOTICE Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs 34 Nm 7 Reattach the oil line 57 MAINTENANCE Oil and Filter Change 8 Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it 9 Lubricate the gasket on the new filter with a film of new engine oil Check to make sure the gasket is in good condition Make sure the gasket from the old filter is not still on the engine 10 Install the new oil filter After the filter contacts the engine Filter surface turn it 1 2 to 3 4 turn by hand 11 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case Tip The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 12 Reinstall the drain plug and torque to 14 ft Ibs 19 Nm 13 Remove the dipstick Add the recommended oil See page 56 Rein stall the dipstick Tip If the sump is not drained add about 1 3 4 quarts initially 14 Place the transmission in neutral Lock the parking brake 15 Prime the oil pump using the procedure on page 59 Then stop the engine and inspect for leaks 16 Remove the dipstick and check the oil level Add oil as needed Maintain the o
14. 3 tablespoons 30 40 ml of engine oil into the hole Use a section of small hose and a small plastic squeeze bottle filled with the pre measured amount of oil Reinstall the spark plug Torque to specification Apply dielectric grease to the inside of the spark plug cap Reinstall the cap Turn the engine over several times using the electric start Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil If Polaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops 99 MAINTENANCE 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 Make sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 Be sure the storage area is well ventilated Cover the machine with an appropriate cover Do not use plastic or coated materials as they do not allow proper ventilation to prevent condensation corrosion and oxidation 100 MAINTENANCE Transporting the Vehicle Follow these procedure
15. 31 Engine Fogging 99 Engine Idle RPM Adjustment 69 Engine Oil 56 Equipment Modifications 7 Exhaust Emission Control System 49 Eye Protection 9 F Fluid Brake 62 Foot Brake Auxiliarv 27 Fuel Filter 452 323 si uwa 28 Fuel Safety 0 000000 11 Fuel Tank Cap 28 Fuel Valve 0 00 28 G Gasoline Handling 11 Gear Selector 000000 29 GIOVES is aj AAEE 9 H Handlebar Adjustment 68 Hauling Cargo 46 47 Headlamp Replacement 75 Headlight Switch 23 Helmet arearen i arannana ENS 8 113 INDEX l Idle RPM Adjustment 69 Immersion enano neunana 84 Indicator Lights 23 J Jetting Chart 103 K Key Switch 005 22 We PUP e teats a E 42 L Lights A ik ie e neS 75 76 Headlamp 75 Indicator Lamp 76 Taillight Brakelight 76 Load Distribution 47 Lubrication Guide 55 M Maintenance Chart 50 54 Maintenance Chart Kev 51 Modifications 00 7 N Noise Emission Control System 49 0 Oil Engines eree Miss tae eSa 56 Transmission 60 61 Oil and Filter Change 57 59 Oil Level Engine 56 Oil Pump Priming 59 Oil Recommendations Engi
16. at the front and rear of the battery 91 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge 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 Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 104 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery o jab Nee fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 92 MAINTENANCE 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 Charge as needed to raise the s
17. clean cloth Safe Range 4 Reinstall the dipstick completely Make sure the cap is fully seated C to keep the angle and depth of the stick consistent 5 Remove the dipstick and check Add Oil Safe the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 6 Reinstall the dipstick 56 MAINTENANCE 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 2 Start the engine Allow it to idle for two to three minutes Stop the engine 3 Place a drain pan under the oil tank Remove the drain plug Allow the oil to drain completely CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 4 Reinstall the drain plug with a new sealing washer Torque to specification See Sealing page 56 Washer Tip The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 5 Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank Clean the fitting NOTICE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 6 Reinstall the screen fitting and rotate the fitting clock wise a minimum of 2
18. conven tional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle BO ONO d 90 MAINTENANCE 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 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 ONO Now On conventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Install the battery cover Secure the battery hold down strap Verify that cables are properly routed Cables should be safely tucked away
19. for approximately five minutes Stop the engine 3 Turn the carburetor idle screw in clockwise to raise RPM Turn the screw out counterclockwise to Adjuster lower RPM 69 MAINTENANCE Drive Chain Drive Chain Lubrication The drive chains are equipped with o ring sealed permanently greased pins and rollers However the outer surfaces of the roller must be lubri cated Always inspect the drive chain prior to operating the vehicle Check for damaged or missing o rings or damaged rollers Also check for correct slack adjustment 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 NOTICE Washing the drive chain with a high pressure washer or gasoline can cause damage to the o rings causing premature wear and drive chain failure Do not use a high pressure washer or gasoline to clean the drive chain 70 Drive Chain Rear Drive Chain Slack MAINTENANCE 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 5 mm 10 mm deflection NOTICE Adjusting or operating the vehicle with improper rear drive chain slack can result
20. in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications 3 16 3 8 5 mm 10 mm Use the following procedure if adjustment is required 1 Remove the chain guard 2 Loosen the chain guide 3 Loosen the two eccentric locking bolts 4 Loosen the caliper mounting bolt located on the left side of the swing arm 5 Insert a pin punch through the sprocket hub and into the eccentric housing Pin Punch ih Locking Bolts 71 MAINTENANCE Drive Chain Rear Drive Chain Slack 6 Roll the vehicle forward or back ward to adjust the chain slack to the proper tension See the illustration for proper splice link clip opening position 7 Tighten the eccentric locking bolts to 30 ft Ibs 41 Nm for machines without the hitch and 45 ft lbs 61 Nm for machines with a hitch 8 Tighten the caliper mount bolt to 15 ft Ibs 20 Nm 9 Remove the pin punch 10 Roll the vehicle forward checking chain tension in several places around the chain Tip The chain is adjusted correctly when the tightest portion of the chain has approximately 3 8 10mm deflection 11 Position the chain guide to allow 1 8 3 mm clearance and tighten the retaining bolt to 5 ft Ibs 7 Nm 12 Reinstall the chain guard Position 72 MAINTENANCE Cooling System The engine coolant level is controlled or maintained
21. more information about Quadricycle safety contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www polarisindustries com 17 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle 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 WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough ter rain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175
22. operation Indicator lights switches Ensure operation 22 Engine stop switch Ensure proper operation 22 Drive chain Check condition slack lubricate as 70 needed Air filter pre filter Inspect clean 80 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 23 tric grease when lamp is replaced 75 Brake light tail lamp Check operation apply Polaris dielec 76 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 8 33 OPERATION Starting the Engine 1 2 3 Tip 4 Dis Tip 6 Tip 34 Position the vehicle on a level surface outdoors or in a well venti lated area Place the transmission in neutral Lock the parking brake The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged Turn the fuel valve on Sit on the vehicle Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled If the engine is cold pull the Keir j SO choke knob out until it stops If the knob doesn t stay where positioned increase the ten sion by rotating the tension adjusting nut clockwise The variable choke is fully on when Choke g the knob is pulled completely out Knob The choke is off when the knob is pushed completely in The choke g a can be adjusted gradually depend Adjustin ing on how much c
23. procedure for spark plug installation Torque to specification 82 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 A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect throt tle body carburetor adjustments 83 MAINTENANCE 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 1 Move the vehicle out of the water 2 Turn the fuel valve off 3 Check the air box If water is present dry the air box and replace the filter with a new filter 4 Remove the spark plug 5 Loosen the carburetor drain screw and drain the carburetor 6 T
24. 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 86 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 Similarly if the engine speed decreases the amount of cen trifugal force decreases reducing the amount of belt pinch This begins to occur at speeds of less than 5 MPH 8 km h due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h the engine would be running at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engage ment speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail If the vehicle will be operated for extended periods below 5 MPH 8 km h or for towing loads we recommend that you install a one tooth smaller counter shaft sprocket to raise the operating RPM far enough above the engagement RPM to reduce heat caused by incomplete engagement Reducing the tem
25. the registration for warranty THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WAR RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 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 that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any dam ages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion
26. the tank neck e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Turn the fuel valve off whenever the vehicle is stored or parked A Never start the engine or let it run in an enclosed area Operate this vehicle only outdoors or in well ventilated areas A Always inspect your vehicle before each use to verify that it s in safe operating condition Follow the inspection and maintenance procedures outlined in this manual See page 33 A Always wear an approved helmet that fits properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants 11 SAFETY Operator Safety A Never consume alcohol or drugs before or while operating this vehicle A Keep both hands on the handlebars Keep both feet on the footrests A Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers 12 SAFETY Operator Safety A Never carry a passenger on the rear rack Ejection from the vehicle or contact with moving components can result in serious injury or death A 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 A Never operate at excessive speeds
27. 0 SLOTADE ase Wa A ech ee ees 92 Boots orf a a 9 Brake Parking Brake 26 Brake Check fay 3 os cess adean estes 64 Brake Fluid 62 63 Brake Fluid Auxiliary Foot Brake 63 Brake Fluid Hand Brake 63 Brake Leveti soree nran Ein A 25 Brake Maintenance 62 64 Brake Foot 27 Break In Period 30 31 Breather Filter 81 Cc Carburetor 0000000 ee 69 Carburetor Adjustment 69 Cat BO Is kesa Hate ke atk eres ee 46 47 Choke i Mei nee oe an 28 Chrome Wheel Care 97 Cleaning and Storage 95 100 Clothing Se iiss sta ore a EW ok 9 Clutching Chart 103 Compression Damping Rear 66 Coolant Bottle 73 Coolant Radiator 74 Cooling Svstem 73 74 Corrosion Removal Chrome 97 D Drive Belt Wear Bum 105 Drive Chain 70 72 Drive Chain Lubrication 70 Drive Chain Slack 71 72 Drivetrain Break In 31 D Driving Downhill 41 Driving in Reverse 45 Driving on a Sidehill 40 Driving on Slippery Surfaces 38 Driving Over Obstacles 44 Driving Procedures 36 Driving Properly 36 Driving Through Water 43 Driving Uphill 39 E Electromagnetic Interference 49 Engine Break In
28. 376 18 SAFETY Safety Labels and Locations Discretionary Warning General Warning Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 25 degrees 25 To pre 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 To prevent loss of control avoid sudden braking or sharp turns 7175511 19 SAFETY Safety Labels and Locations Age 16 Warning No Passenger Warning Tire Pressure Load Warning Clutch Cover Warning No Passenger Warning WARNING NEVER ride as a passenger i es can cause a loss of control resulting in SEVERE INJURY or 7175378 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 Cold tire pressure Front 4 0 psi 27 6 kPa Rear 3 0 psi 20 7 kPa e Maximum weight capacity 275 Ibs 125 kg 7175443 20 SAFETY 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 7175374 Clutch Cover Warning WARNING e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed e Do not modify engine or clutch Doing so can c
29. 79 06 WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification 78 MAINTENANCE Tires Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service Item Torque Specification Front Wheel Nuts 27 ft Ibs 37 Nm Rear Wheel Nuts 50 ft Ibs 68 Nm 79 MAINTENANCE Air Filter 1 80 Position the vehicle on a level surface Place the transmission in gear Lock the parking brake Remove the seat Pre Filter Release the air box cover clips and remove the air Main Filter box cover Loosen the clamp and remove the filter Remove the pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Replace the main filter if needed Reinstall the air filter into the air box Tighten the clamp but do not over tighten as filter damage could occur Reinstall the air box cover and the seat MAINTENANCE Breather Filter 1 Remove the clamps and pull the breather filter out of the hoses It s not necessary to remove the lower hose from the engine rss 2 Inspect the filter for debris GA wo Blow gently through the filter in A Breather Filter Fe the direction of the arrow to X check for clogging Replace if
30. Operation is 2 2 Lia e eer we ie eed 30 Emission Control Systems 49 Maintenance 000e eee eens 50 SpecificationS 00 cece eee eee 102 Polaris Products 00000e cease 104 Troubleshooting 0020ee eee eee 105 Warranty ia eee eee ae 109 Maintenance Log 5 00ee0es 111 NAEK eee a e e aa eae 113 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 A 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 CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death This vehicle is not a toy and can be hazardous to operate A collision or rollover can occur quickly even during routine maneuvers if you fail to take proper precautions e Read
31. Pantone 425 C Scrambler 500 2X4 International Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Pantone 425 C AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVERCARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS PE3ZLARIS For vour nearest Polaris dealer The Way Out visit www polarisindustries com Polaris Sales Inc 2100 Hwv 55 Medina MN 55340 U S A Part No 9922077 Rev 02 Printed in U S A 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 e Snowmobiles e All terrain vehicles ATVs e Quadricycles e RANGER utility vehicles e Vi
32. Tires AWARNING 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 Refer to the specifications section beginning on page 102 for recom mended tire type size and pressure Wheel and Hub Tightening Wheel hub and bearing tightness and spindle nut retention are critical items These services must be performed by an authorized dealer Tire Tread Depth i Always replace tires 3mm Z when tread depth is worn to 3 mm or less PN A 77 MAINTENANCE Tires Wheel Removal 1 4 Position the vehicle on a level surface Place the transmission in gear Lock the parking brake Loosen the wheel nuts slightly Safely place jackstands under the vehicle Remove the wheel nuts Remove the wheel Wheel Installation 1 Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation Install the wheel nuts finger tight On vehicles with tapered rear wheel nuts make sure the tapered ends of the nuts fit into the tapers on the wheels Lower the vehicle to the ground Torque the wheel nuts to specification page
33. ain d i tain the fluid level between the maxi mum and minimum marks The brakes should feel firm when thev re applied Spongv or weak brakes mav indicate a fluid leak or low fluid level A low fluid level mav also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongv or weak brakes See vour dealer for service 63 MAINTENANCE 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 2 Check the brakes for excessive travel or spongy feel 3 Check the brake pads for wear dam age or looseness Replace pads when they are worn to 1 mm 4 Check the security and surface condition of the brake discs 64 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 3 6 mm toe out WARNING 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 1 Position the vehicle on a level surface 2 Set the handlebars in a straight ahead position and secure them in this position 3 Place a chalk mark on the center line of the front tires ap
34. ause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7172563 Reverse Override Warning WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse 7175486 21 FEATURES AND CONTROLS Switches Headlight Switch 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 Always release the throttle before pressing the override switch The override switch also allows activation of All Wheel Drive in reverse if the AWD switch is on Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine Car B quickly The engine will not start or run N when the switch is off OFF RUN OFF Both the main switch and the engine stop switch will shut off all electrical power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 34 for starting pro cedures 22 FEATURES AND CONTROLS Switches Headligh
35. brake fade and the possibility of accident Do not store opened brake fluid Properly discard any unused portion 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 If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill 62 MAINTENANCE Brakes Brake Fluid Hand Brake Check the brake fluid level in the Master Cylinder 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 Do not overfill 1 Position the vehicle on a level surface Make sure the han dlebars are straight al 2 View the fluid level through the indicator window eye on the top of the master cylinder The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed Do not overfill Brake Fluid Auxiliary Foot Brake Check the brake fluid level fre quently for the auxiliary brake sys tem The reservoir is located under the seat or near the foot brake M
36. by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the bottle past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle 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 Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle 1 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 2 Add coolant as needed Recovery Bottle 73 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine
37. check the level O lt lt 4 Add the recommended lubricant to bring the level Safe into the safe operating Range range 5 Reinstall the dipstick 60 Transmission Oil Oil Change 1 2 10 11 Position the vehicle on a level surface Place a drain pan beneath the transmission oil drain plug area Loosen the jam nut Turn the adjuster bolt in to allow the removal of the drain plug Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings After the oil has drained com pletely install a new sealing washer and reinstall the drain plug Torque to specification Turn the adjuster bolt out until it touches the frame and then turn an additional 1 2 turn MAINTENANCE O Wei uoe o Cn W Q S Xi H B NS a l i Drain Plug Tighten the jam nut securely while holding the adjuster bolt Remove the dipstick Add the recommended lubricant until the oil level is between the upper and lower limits Do not overfill Reinstall the dipstick Check for leaks Discard used oil properly 61 MAINTENANCE Brakes Brake Fluid A An over full master cylinder may cause brake drag or brake lock up which could result in an accident Maintain brake fluid at the recommended level Do not overfill Once open a bottle of brake fluid absorbs moisture from the air which causes the boiling temperature of the brake fluid to drop This can lead to early
38. ctory motorcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Please see your dealer for all of your service needs during and after the warranty period For more information about Polaris visit us online at www polarisin dustries com POLARIS The Way Out 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 improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in Taiwan 2009 Scrambler 500 2X4 International Owner s Manual P N 9922077 2 TABLE OF CONTENTS Introduction i ii rkant kriet d dad wees 4 Safety Li a in A d B Ot eens 7 Features and Controls 22
39. e 14 oz 4 cartridge 2871460 Starter Drive Grease 2 0z 59 ml 2871515 Premium U Joint Lube 3 0z 89 ml 2871551 Premium U Joint Lube 14 oz 4 l 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 0z 185 ml 2872348 Chain Lube Aerosol 16 oz 47 Additives Miscellaneous 2871326 Carbon Clean Plus 12 0z 355 ml 2870652 Fuel Stabilizer 16 0z 47 l 2872189 DOT4 Brake Fluid 12 0z 355 ml 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger 104 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Starting out going up a steep incline Solution Use low range if equipped or turn around using the K turn see page 42 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range if equipped more frequently Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only if equipped Utility use plowing Use low range only if equipped Stuck in mud or snow Cl
40. e damping adjustments The factory setting is at 10 clicks from fully closed The compression damping clicker is located on the end of the shock reservoir 1 Turn the clicker clockwise 1 to IIL increase compression damping am 2 Turn the clicker counter clockwise 2 to decrease compression damp ing 66 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 Slide the boots off the inline cable adjuster sleeve Loosen the adjuster locknut 2 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 3 Tighten the lock nut and slide the boots over the cable adjuster until 1 6 3 MM they touch at the midpoint of the i adjuster Tip Engine RPM should not increase when steering is turned full left or right Readjust cable freeplay if this occurs 67 MAINTENANCE Handlebars WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service The handlebars can be adjusted for rider preference 1 Remove the handlebar cover Handlebar Bolts Loosen do not remove the four handlebar clamp bolts Adjust the handlebar to t
41. e climbing a hill never back it down the hill Use the K turn to turn around 42 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill Start the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the brake lever until the vehicle is on more level ground OPERATION 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 Choose a crossing where both banks have gradual inclines Avoid operating through deep or fast flowing water After leaving water test the brakes Applv them lightly several times while driving a lt A slowly The friction Maximum Depth will help dry out the pads NOTICE Major engine damage can result if
42. e idles smoothly push the choke completely in 35 OPERATION Driving Procedures XN BO CON ON ee 36 Wear a helmet and eye protection See page 8 Sit upright Keep your feet on the footrests Keep both hands on the handlebars Squeeze the brake lever Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the brake lever Slowly squeeze the throttle lever toward the handlebar to begin driving Squeeze the throttle lever further to increase speed Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 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 A Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 37 OPERATION Driving on Slippery Surfaces Sideways Turn in skid i direction of skid C Ie C y SF Sy LET S or O Co cC S AS c y Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 3 38 Do not operate on excessively rough s
43. e lever several times to purge carbon from the system 7 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 8 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 6 9 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 10 Place the transmission in neutral Lock the parking brake Repeat steps 6 to 8 until no more particles are expelled 11 Stop the engine Allow the arrestor to cool 12 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 85 MAINTENANCE PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe e Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e This PVT
44. e of choke Inspect clean and or replace spark plugs Fouled or defective spark plug s Inspect clean and or replace spark plugs Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low batterv voltage Recharge the batterv to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See vour dealer Electronic throttle control malfunction See vour dealer Other mechanical failure See vour dealer Overheated engine 108 Clean engine exterior see vour Polaris dealer WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record
45. ear brake as well and then lock the parking brake Dismount on the uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around and remount following the pro cedure described on page 42 39 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 Slow down Avoid hills with excessively slippery or loose surfaces Avoid crossing the side of a steep hill Shift body weight uphill Keep your feet on the footrests De l O If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 40 OPERATION Driving Downhill 25 Maximum When driving downhill follow these precautions Avoid steep hills 25 maximum Avoid hills with excessively slippery or loose surfaces Shift body weight uphill Drive straight downhill Slow down Never go down a hill at high speed Avoid going down a hill at an angle which can cause the vehicle to pitch sharply to one side 7 Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of con trol ON i eB JA 41 OPERATION Turning Around on a Hill K Turn If the vehicle stalls whil
46. efore operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the vehicle if leaving it parked on a hill Another option is to park the vehicle in a sidehill position Never depend on the parking brake alone if the vehicle is parked on a hill Always block the wheels to prevent rolling 26 FEATURES AND CONTROLS Auxiliary Foot Brake A 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 The rear wheels may skid and slide sideways causing loss of control which may result in serious injury or death The auxiliary brake serves as a backup to the main brake sys tem if the main system becomes inoperative The auxiliary foot brake is located on the inside of the right footrest Operate this brake with your right foot If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Auxiliary Foot Brake 27 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
47. he desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right Torque the front two bolts to 14 17 Nm then torque the rear two bolts Tip A gap of up to 3 mm should remain at the rear bolts 68 MAINTENANCE 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 Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets and clutch components available from your Polaris dealer are required for operation above 1800 meters and at temperatures below 4 degrees C Tip Continuous operation of the engine without proper jetting when required can cause poor performance overheating or engine damage See your Polaris dealer for more information about jetting Carburetor Engine Idle RPM Adjustment If the engine idle speed is not satisfac tory and all other conditions are favor L gt able the carburetor can be adjusted De 1 Position the vehicle on a level sur e K gt Ep face Place the transmission in gear amp Lock the parking brake F 2 Start the engine Allow it to idle
48. hicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 46 OPERATION 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 ve
49. hicle speed of approximately 10 miles per hour 16 km h Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 50 MAINTENANCE Periodic Maintenance Chart A Improperly performing the procedures marked with a could result in 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 gt Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions M Have an authorized Polaris dealer perform these services 51 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks
50. hicle warning labels Never exceed the specified weights Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Towing Loads Towing is approved OFF ROAD ONLY Operating a Quadricycle trailer combination on public roads is prohibited Do not exceed the maximum capacities when towing Do not tow any trailer on a grade steeper than 15 Always attach a towed load to the hitch point Remove the hitch from the vehicle when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight e The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity e The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle 47 OPERATION Parking on an Incline Avoid parking on an incline If it s unavoidable follow these precau tions 1 sisa a 48 Stop the engine Place the transmission in gear Lock the parking brake Always block the rear wheels on the downhill side Turn the fuel valve off EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with governmental n
51. hoke is needed Nut for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine compo nents Move the engine stop switch to RUN Do not press the throttle while starting the engine OPERATION 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 10 Tip 11 damage Allow the engine to warm up for several minutes before operating the vehicle If the engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts If a warm engine has cooled to a point where it does not readily start inter mittent use of the choke knob pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engin
52. il level in the safe range Do not overfill 17 Discard used oil and filter properly 58 MAINTENANCE 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 2 5 cm Relief been disconnected Slit 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 relief slit 2 Run the engine for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation Jf you do not hear air the line has not bled and you ll need to repeat the priming procedure 59 MAINTENANCE 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 Lubricant Capacity Drain Plug Torque Transmission Premium AGL Synthetic 11 3 oz 14 ft Ibs Gearcase Lubricant 334 ml 19 Nm Oil Check 1 Position the vehicle on a level surface 2 The transmission oil dipstick is located on the right side of the vehi cle Remove the dipstick and wipe it clean 3 Reinstall the dipstick completely then remove cI it and
53. imbing over large objects from a stopped position Shift the transmission to low range if equipped Care fully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 88 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph 48 km h for one mile 1 6 km Operate 5 miles 8 km or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 31 105 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Tripped circuit breaker Solution Reset the breaker Low batterv voltage Recharge the batterv to 12 8 VDC Loose batterv connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Turn fuel valve to reserve refuel Clogged fuel valve or filter Inspect and clean or replace Water
54. ion loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period 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 Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Do not operate at full throttle or high speeds during the first three hours of use 30 OPERATION Break In Period Engine and Drivetrain Break in 1 2 Fill the fuel tank with gasoline See page 28 Alwavs exercise extreme caution whenever handling gasoline Check the oil level See page 56 Add oil as needed to maintain the level in the proper range Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling Varv the throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the dailv pre ride inspection checklist See page 33 Pull only light loads if equipped with a hitch Change both the oil and the filter at 20 hours or one month which ever comes first PVT Break in Clutches Belt A proper b
55. is present in fuel Drain the fuel svstem and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Overuse of choke Clogged fuel filter Inspect clean and or replace spark plugs Replace the filter Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectiv installed spark plug wires See vour dealer Incorrect ignition timing See vour dealer Mechanical failure See vour dealer 106 Engine Pings or Knocks TROUBLESHOOTING Possible Cause Poor quality or low octane fuel Solution Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Engine Runs Irregularly Stalls or Misfires Possible Cause Fouled o
56. ities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 89 MAINTENANCE Battery Battery Removal Place the transmission in gear Lock the parking brake Disconnect the battery hold down strap Remove the battery cover On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the vehicle Be careful not to tip a
57. limited to mow ers blades tires sprayers and large racks may change vehicle handling Use only Polaris approved accessories Know their function and effect on the vehicle SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury Eye Protection 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 Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles 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 Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with
58. lippery or loose terrain Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward OPERATION 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 Always check the ter rain carefully before ascending any hill 4 Avoid hills with exces sively slippery or loose surfaces 5 Keep both feet on the footrests 6 Shift body weight uphill Drive at a steady rate of speed to avoid stalling Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed 10 Be alert Be prepared to take emergency action This may include dismounting quickly If all forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary brake as well then lock the parking brake OAs If the vehicle begins rolling downhill never apply engine power Never apply the rear brakes while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary r
59. nen ia a eh ey 56 Transmission 60 Oil Specifications Engine 56 Operator Safety 10 17 Override Switch 22 114 P Parking Brake 26 Parking on an Incline 48 Periodic Maintenance Chart 50 54 Polaris Product List 104 Polishing the Vehicle 96 Pre Ride Checklist 33 PVT Break In 31 PVT Divin ia Sens me mer ai 88 PVT Svstem 000000 86 88 R Reverse Operation 45 Riding Gear 8 9 S Safe Operation Practices 32 Safety Labels 18 21 No Passenger Warning 20 Age 16 Warning 21 Clutch Cover Warning 21 Discretionary Warning 19 General Warning 18 Reverse Override Warning 21 Tire Pressure Load Warning 20 Safety Training 7 Seyre USE pa Missin ee a A 50 SAMET E TE asta a Sten a ate ee 29 Sidehilling LL 40 Signal Words 0 00 4 Spark Arrestor 0 00000 85 Spark Plugs 000 82 83 Spring Preload Rear 66 Starting the Engine 34 35 Steering Assembly 66 Storage 95 100 Suspension Adjustments Rear 66 Switches sirince 22 23 Engine Stop Switch 22 Headlight Switch 23 Main Key Switch 22 T Throttle Cable Freeplay 67 Throttle Lever
60. occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 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 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Stop the engine 5 Turn the fuel valve off 6 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 57 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Clean or replace the breather filter 4 Drain the sediment tube 98 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 50 e Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill Fog the Engine 1 Treat the fuel svstem with Polaris Carbon Clean See page 98 Support the front end of the machine so the engine is level or tilted slightly rearward Remove the spark plug Pour 2
61. oise level requirements Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition 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 Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC 49 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart 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 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average ve
62. oper tire pressure Never operate a damaged Quadricycle After any overturn or acci dent have a qualified service dealer inspect the entire machine for possible damage Never operate the vehicle on a frozen body of water Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area Do not touch hot exhaust system components Always keep com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use Pre Ride Checklist OPERATION Failure to inspect and verify that the vehicle is in safe operating condi tion before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition protective clothing Item Remarks Page Brake system lever travel Ensure proper operation a Brake fluid Ensure proper level 63 Auxiliary Foot brake Ensure proper operation 27 Front suspension Inspect lubricate if necessary 55 Rear suspension Inspect lubricate if necessary 55 Steering Ensure free operation Tires Inspect condition and pressure 77 Wheels fasteners Inspect ensure fastener tightness 77 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels z8 Coolant level Ensure proper level 73 Coolant hoses Inspect for leaks Throttle Ensure proper
63. or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the Quadricycle The exclusive remedy for breach of this war ranty shall be at Polaris exclusive option repair or replacement of any defective materi als or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 109 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling
64. pecific grav ity to 1 270 or greater 3 Reinstall the battery See page 91 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion 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 Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the following guidelines fo
65. perature inside the clutch cover greatly extends the life of the PVT components belt cover etc Tip Avoid heavy pulling and extended low speed operation 87 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 3 Start the engine Place the transmission in neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission into forward gear 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 88 MAINTENANCE Battery AWARNING 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 AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quant
66. polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 96 MAINTENANCE 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 Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 97 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could
67. proximately 25 cm from the floor or as close to the hub axle center line as pos sible Make sure both marks are the same distance from the floor 4 Measure the distance between the marks and record the measurement 1 5 Move the vehicle until the chalk marks are at the rear of the tires even with the hub axle center line 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 Ifyou discover improper alignment see your Polaris dealer for ser vice 65 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 shock compression damping may be adjusted to suit different riding condi tions and operator weight Spring Preload 1 Raise and safely support the rear of the vehicle off the ground to allow the suspension to fully extend Adjusting Ring 2 Loosen the jam nut and back it away from the adjusting ring 3 Turn the adjusting ring counter clockwise 1 to increase preload Turn the ring clockwise 2 to decrease preload Jam 4 Tighten the jam nut firmly against Nut the adjuster ring Compression Damping Use a flat blade screwdriver to mak
68. r defective spark plug s Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Clogged air filter Replace with recommended fuel Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your dealer Possible Rich Fuel Cause Overuse of choke Solution Inspect clean and or replace spark plugs Fuel is verv high octane Replace with lower octane fuel Incorrect jetting See vour dealer 107 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Turn fuel valve to reserve refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Overus
69. r recharging 93 MAINTENANCE Battery Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of a Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 94 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping the vehicle clean will extend the life of components NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces 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 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spo
70. re pressure A Always travel slowly when operating on unfamiliar terrain Use extra caution A Always follow the procedures outlined in this manual for driving in reverse See page 45 A Use caution when operating on rough slippery or loose terrain A Always follow the procedures outlined in this manual for operating over obstacles See page 44 A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 38 16 SAFETY Operator Safety A Never operate this vehicle on a frozen body of water A Never modify a Quadricycle through improper installation or use of accessories A Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking A 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 A Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system A Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting For
71. reak in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 31 OPERATION Safe Operation Practices 1 2 10 11 12 13 14 32 Complete the recommended safetv training before operating this Vehicle See page 7 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 Never carry a passenger on this vehicle Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Avoid sudden turns or swift movement of the handlebars when operating on pavement Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating this vehi cle Always use the size and type of tires specified for your vehicle Always maintain pr
72. s a residue causing a hot spot that will shorten the life of the lamp 1 Remove the wire harness connector from the back of the headlight CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 2 Grasp the bulb housing and turn it counterclockwise to remove the bulb 3 Apply dielectric grease to the light bulb socket before installing the new bulb Install the replacement bulb into the headlight housing and rotate clockwise firmly Tip The bulb must be positioned so the harness installs into the lamp at the bot tom 4 Reinstall the connector to the back of the headlight 75 MAINTENANCE Lights Taillight Brakelight Lamp Replacement 1 4 5 Remove the taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly Remove the lamp Apply dielectric grease to the socket and install the new lamp Test the taillight brake light for kol proper operation Reinstall the gasket and lens cover Indicator Lamp Replacement 1 2 76 Remove the instrument panel if necessary to access the back of the indicator panel Using a small straight blade screwdriver turn the base of the bulb 1 4 turn counterclockwise Using a needle nose pliers or similar tool pull the lamp out of the indicator panel housing Insert the new bulb and seat it by turning it 1 4 turn clockwise Reinstall the instrument panel if removed MAINTENANCE
73. s when transporting the vehicle F Fi 1 Stop the engine y 2 Place the transmission in gear i 3 Lock the parking brake 4 Turn the fuel valve off 5 Secure the fuel cap oil cap and seat 6 Remove the key to prevent loss during transporting 7 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front bumper racks or handle bars 101 SPECIFICATIONS Scrambler 500 2X4 Maximum Weight Capacity 305 Ibs 138 kg includes weight of opera tor cargo and accessories Dry Weight 530 Ibs 240 kg Fuel Capacity 3 5 gal 13 21 Engine Oil Capacitv 2 qts 1 9 1 Transmission Oil 11 3 oz 334 ml Coolant 2 25 qts 2 13 1 Front Rack Capacitv Accessorv 30 Ibs 13 6 kg Maximum Rear Rack Capacitv Accessorv Hitch Tongue Weight Capacitv 60 Ibs 27 2 kg Maximum 85 Ibs 38 6 kg Rear rack capacitv and tongue weight not to exceed 60 1bs 27 2 kg Hitch Towing Rating 850 Ibs 385 6 kg Unbraked Trailer Towing Capacity 1210 Ibs 549 kg Overall Length 75 in 190 5 cm Overall Width 46 in 117 cm Overall Height 47 in 114 cm Wheelbase 48 in 122 cm Ground Clearance 5 5 in 14 cm Minimum Turning Radius 75 in 190 5 cm unloaded Engine Model Number Type 4 Cycle Single Cylinder
74. shoulder pads provide the best protection SAFETY Operator Safety AWARNING Failure to operate the vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures A Read and understand all warnings cautions and operating procedures in this manual and on the safety labels before operating this vehicle 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 they have read and understand this manual and all product labels and have completed a certified safety training course A Never allow anyone under 16 years of age to operate this vehicle KO 10 SAFETY Operator Safety A Handling Gasoline Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e 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 e Do not overfill the tank Do not fill
75. state law 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 Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 110 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 111 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 112 A Air Filter 00 0 0 ce cee eee 80 B Battery cece cece eens 89 94 Charging Conventional 93 Charging Sealed 93 94 Fluid Conventional 92 Installation 91 Removal He seines i sea 9
76. t 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 Indicator Lights With the engine running verify the function of all indicator lights before each use of the vehicle Tip The taillight is on whenever the main switch key is on Turn the key off to prevent battery drain Reverse Indicator High Temperature Warning Neutral Indicator displays if engine overheats 23 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 A Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Check the lever for proper operation before starting the engine Check occasionally during operation Do not start or operate a vehicle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 24 FEATURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front
77. the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 50 The following areas need special attention engine oil transmission oil front and rear gearcases if equipped and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 84 then see your dealer for service at the first opportunity If it s unavoidable to enter water deeper than the footrest level e Proceed slowly Avoid rocks and obstacles Balance your weight carefully Avoid sudden movements Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 43 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 3 4 44 Alwavs check for obstacles before operating in a new area Be alert Watch the terrain Use extra caution Never operate over large obstacles Avoid hazards such as logs rocks and low branches OPERATION Driving in Reverse Follow these precautions when operating in reverse eS ON oe A Always check for obstacles or people behind the vehicle Always avoid backing downhill
78. this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle e Never operate this vehicle without proper instruction Take a training course e This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age e This vehicle is approved for OFF ROAD TOWING ONLY Operating a Quadricycle trailer combination on public roads is prohibited 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 E8 Z HHH Key Number Vehicle Model Number Frame VIN Engine Serial Number right front side of engine crankcase Key Number SAFETY Safety Training When you purchased your new Polaris vehicle your dealer offered a hands on safety training course 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 The warranty on your Polaris vehicle may be terminated if any equip ment has been added or if any modifications have been made that increase speed or power The addition of certain accessories including but not
79. ts Washing Tips e Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 95 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components Avoid directing the water stream at the following items e Wheel bearings e Electrical components wiring e Radiator e Switches and controls e Transmission seals e Cab and body panels e Brakes e Labels and decals 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 Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system 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 e Avoid the use of automotive products some of which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and
80. urn the engine over several times using the electric start 7 Dry the spark plug Reinstall the plug or install a new plug 8 Tighten the carburetor drain screw Turn the fuel valve on 10 Attempt to start the engine If neces sary repeat the drying procedure Drain Screw 11 Have the vehicle serviced by your dealer promptly whether you succeed in starting it or not 12 If water has been ingested into the transmission follow the proce dure on page 88 for drying 84 MAINTENANCE Spark Arrestor AWARNING 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 Do not stand behind or in front of the vehicle while purging Never go under the vehicle while it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Position the vehicle on a level surface 2 Place the transmission in Exhaust neutral Outlet Tp 3 Lock the parking brake i AN 4 Remove the arrestor clean Clean Out Plug out plug from the bottom of the muffler 5 Start the engine 6 Quickly squeeze and release the throttl
81. whichever comes first Hours Calendar Kilometers E Steering Pre Ride Make adjustments as need 7 ed See Pre Ride Checklist gt jFront suspension Pre Ride on page 33 gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride P Engine oil level Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element gt Brake pad wear 10 Monthly 100 160 Inspect periodically a Battery 20 Monthly 200 320 Check terminals clean test gt Front gearcase oil 25 Monthly 250 400 Inspect level change yearly if equipped gt Transmission oil 25 Monthly 250 400 Inspect level change yearly gt Engine breather 25 Monthly 250 400 Inspect clean if needed E jfilter if equipped gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service Mm Have an authorized Polaris dealer perform these services 52 Periodic Maintenance Chart MAINTENANCE

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