Home

Polaris 9922461 Offroad Vehicle User Manual

1. Number 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 I 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 I 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2870465 Pump for Gallon 3 8 I Jug 2876251 Demand Drive LT Premium Fluid 8 0z 237 ml Coolant 2871323 60 40 Coolant gal 3 8 I 2871534 60 40 Coolant qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 0z 185 ml 2872348 Chain Lube Aerosol 16 0z 473 ml Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger 109 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Starting out going up a steep incli
2. 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 83 MAINTENANCE Cooling System The engine coolant level is controlled or maintained 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 109 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
3. At least 13 hours verify state of charge 096 2596 11 5 volts or less Needs charge with desulfating charger At least 20 hours 101 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various 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 spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish 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 102 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The wat
4. gt Brake fluid level Pre Ride gt Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt 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 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 10H Monthly 100 160 Inspect periodically n 58 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Battery 20H Monthly 200 320 Check terminals clean test gt Demand drive fluid 25 H Monthly 250 400 Inspect level change yearly gt Transmission oil 25H Monthly 250 400 Inspect level change yearly gt Engine breather 25 H Monthly 250 400 Inspect clean if needed E filter if equipped gt General 50H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Carburetor float 50H 6M 500 800 Drain bowl periodically and bowl prior to storage E Throttle Cable 50H 6M 500 800 Inspect adjust lubricate E ETC Switch replace if necessary W Choke cable 50H 6M 500 800 Inspect adjust lubricate E replace if necessary E Carbureto
5. Check for leaks Reinstall the propshaft shield 69 MAINTENANCE Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the intervals out lined in the Periodic Maintenance Chart beginning on page 57 Maintain the fluid level at the bottom of the fill hole threads See page 109 for the part numbers of Polaris products Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Front Demand Drive LT 9 oz 8 10 ft Ibs 11 ft Ibs Gearcase Premium Fluid 265 ml 11 14 Nm 15 Nm Fluid Check The fill plug is located on the right side of the demand drive unit 1 Position the vehicle on a Fill level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads l 4 Reinstall the fill plug FIL avel Drain Plug Torque to specification Fluid Change The drain plug is located on the bottom right side of the unit 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to specification Add the recommended fluid to capacity Reinstall the fill plug Torque to specification Check for leaks Dispose of used fluid properly BO SON de
6. Pantone 426C scrambler 4X4 Owner s Manual for Maintenance and Safety 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 AWARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance OD RECYCLED The text is printed on 10096 recycled with 4096 post consumer waste PCW Pantone 426c AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle 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 terrain and in turns avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL IN
7. 25 Maximum When driving downhill follow these precautions l 2 3 4 48 Avoid steep hills 25 maximum Shift body weight uphill Drive straight downhill Slow down Excessive speed when traveling downhill can cause loss of control 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 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 1 Stop and lock the parking brake while keeping body weight uphill 2 Leave the transmission in forward and shut off the engine 3 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 5 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 6 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 49 OPERATION Driving Through Water Your ATV can operate through water with a maxi mum recommended depth equal to the bo
8. 56 Emissions Limited Warranty 123 124 Engaging AWD 36 Engine Break In 37 Engine Fogging 106 Engine Idle RPM Adjustment 80 Engine Oil uuuss 63 64 Equipment Modifications 9 Etiquette Trail Riding 39 Exhaust Emission Control System 56 Eye Protection 0 9 F Fluid Brake 32 33 Fluid Demand Drive 70 Foot Brake Auxiliary 31 Front Gearcase Fluid 70 Fuel Filterz c enorm 34 Fuel Safety msporis e ras 11 Fuel Tank Cap 34 Piel Valve iss sce tus RD 34 127 INDEX G Gasoline Handling 11 Gear Selector 0 35 GloV Su iis eem thee 9 H Handlebar Adjustment 74 Hauling Cargo 54 55 Headlamp Replacement 87 Headlight Beam Adjustment 86 Headlight Switch 27 Helmet es vee sive shales ae paces 8 l Idle RPM Adjustment 80 Immersion ii e t i PEE ES 91 Indicator Lights 27 J Jetting Chart suus 115 K Key Switch i csse ems 26 KT ies aee YR eee Ded yee 49 L Lights e eee eee 86 88 Brakelight Replacement 88 Headlamp Replacement 87 Headlight Beam Adjustment 86 Indicator Lamp Replacement 88 Taillight Replacement 88 Lubrication Guide 61 62 M Maintenance Chart
9. 70 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar The auxiliary foot brake is also hydraulic Both brake systems are self adjusting Brake Inspections The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 32 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction mate rial is worn to 1 mm 5 Check the security and surface condition of the disc Side Panel Removal Tip Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times 1 Remove the seat 2 Remove the push pins at the front and rear of the side panel 3 Grasp the rear of the side panel near the rear cab Pull the panel slightly outward downward and rearward to disengage the upper front section 4 To reinstall the side panel align the upper and lower front section with the mating front cab tabs Push the panel upward and forward until the panel is fully seated at the front Lock the rear of the panel into the rear front cab tabs Reinstall the push pins at the front and rear of the side panel 71 MA
10. Follow these precautions when operating over obstacles l 2 Always check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible Never attempt to operate over large obstacles such as rocks or fallen trees 51 OPERATION Driving in Reverse Follow these precautions when operating in reverse Always check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes ightly for stopping Avoid turning at sharp angles Never open the throttle suddenly pto Uh qe USA CE 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 52 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions l Un e Stop the engine Place the transmission in gear Lock the parking brake Always block the rear wh
11. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Fuel Valve The fuel valve is located on the left side of the vehicle below the fender Cap ON For normal operation OFF For vehicle storage and when transporting 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 34 FEATURES AND CONTROLS Automatic 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 ATV is left unattended always place the transmission in gear and lock the parking brake 35 FEATURES AND CONTROLS All Wheel Drive AWD System The All Wheel Drive system is controlled by the AWD switch When the switch is on 2X4 the ATV is in two wheel drive at all times When the switch is on AWD the ATV is in all wheel ad AWD drive and the AWD indicator light Switch will be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose tra
12. blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Safety Warnings AWARNING Failure to operate the ATV 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 Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident The operator must understand how to operate the ATV properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury 10 SAFETY Safety Warnings Handling Gasolin
13. control Engine speed and vehicle move ment are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns ES j to idle when the lever is released f LTD This ATV is equipped with Polaris ed Electronic Throttle Control ETC e gt which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 28 FEATURES AND CONTROLS Brake Lever AWARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always contact your dealer for service before operating the vehicle Squeeze the brake lever toward the handlebar to apply the front and rear brakes These brakes 6 are hydraulically activated disc y type brakes that are activated ETT by only one lever H l o V H FAI de 65 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 29 FEATURES AND CONTROLS Parking Brake Locking the Parki
14. turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly 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 This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 44 OPERATION Driving on Slippery Surfaces i Turn in E d of ski C C C C AX prow C C A 1 LQ SS C C Co cC BY BS CC Q4 Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage AWD before wheels begin to lose traction NOTICE Severe damage to drive train may occur if AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during
15. 57 60 Modifications 04 9 N Noise Emission Control System 56 128 Oo Oil Engine 63 64 Oil Transmission 68 69 Oil and Filter Change 65 67 Oil Level Engine 64 Oil Pump Priming 67 Oil Recommendations 63 Operation on Public Lands 56 Override Switch 26 P Parking Brake 30 Parking on an Incline 53 Periodic Maintenance Chart 57 60 Polaris Product List 109 Polishing the Vehicle 103 Pre Ride Checklist 40 PVT Break In 37 PVT Drying 95 PVT System 93 95 R Reverse Operation 52 Riding Area 39 Riding Gear 8 9 S Safe Operation Practices 38 Safety Labels 22 25 No Passenger Warning 24 4X4 Caution 25 Age 16 Waming 25 Clutch Cover Warning 25 Discretionary Warning 23 General Warning 22 Reverse Override Warning 25 Tire Pressure Load Warning 24 Safety Training 7 Safety Warnings 10 21 Severe Uses cer scum s ur dee 57 S Side Panel Removal 71 Sidehilling lusus 47 Signal Words 24 4 Spark Arrestor 2 92 Spark Plugs 89 90 Spring Ad
16. 804 ZN55 ZX55 SPORTSMAN 550 EFI 2009 2010 80 8 TN55 _DNSS SPORTSMAN X2 TOURING 550 2010 712 MN 76 SPORTSMAN 800 2008 2009 2010 83 6 TN85 DN85 SPORTSMAN X2 TOURING 850 2010 712 J CL76 SPORTSMAN 800 6X6 2009 2010 80 1 ZN85 ZX85 SPORTSMAN 850 EFI 2009 2010 80 4 RH50 HH50 RANGER 500 EFI 4X4 2009 2010 76 5 HH76 RANGER 800 EFI 4X4 2010 76 5 WH76 RANGER 800 EFI CREW 2010 76 5 HR RANGER 800 6X6 2010 76 5 HY _ RANGER HD 800 4X4 2010 76 5 VH76 RANGER RZR 2008 2009 2010 85 8 Authorized Signatory Abe tater T 4 Pamata Alexander A Kennedy Product Compliance Polaris Industries Inc Engineering Operations 301 5th Avenue SW Roseau MN 56751 116 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty 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 w
17. DENTAL 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 ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which Polaris has no responsibility or by acts of God Any qualified repair shop or person may
18. Fluid Demand Drive LT See page 70 Front Prop Shaft Yoke Premium U Joint Lube Grease fittings 3 pumps maximum every 500 miles 800 km before long periods of storage or after pressure washing or submerging Grease Front Hubs Premium Hub Lube Remove set screw in hubs Rotate wheels to 4 o clock position If lubricant is not visible add more Reinstall set Screw Swing Arm P Premium All Season Locate fittings on swing arm and Bushings Grease grease with grease gun Axle Housing Ball Joint gt Premium All Season Locate fitting on back side of struts and Grease grease with grease gun Tie Rod Ends gt Premium All Season Lift boot clean away dirt and grease apply fresh grease by hand and reas semble Perform when suspension action becomes stiff or after washing 61 MAINTENANCE Lubrication Guide Front Prop Shaft Yoke Swing Arm Bushings 4 or 8 o clock position end view 62 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil Polaris recommends the use of Polaris PS 4 PLUS Performance Syn thetic 2W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation See page 109 for the part numbers of Polaris products NOTICE Mixing brands or using a non
19. 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 without proper training or instruction atspeeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle 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 avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 22 SAFETY Safety Labels and Locations General Warning Discretionary Warning Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 25 de
20. apply to you if inconsistent with controlling state law 119 WARRANTY 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 SIX MONTH 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 state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY 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 person 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 Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine d
21. change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Maintain the oil level at the bottom of the fill hole threads See page 109 for the part numbers of Polaris products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission Premium AGL Synthetic 32 oz 14 ft Ibs 14 ft Ibs Gearcase Lubricant 946 ml 19 Nm 19 Nm Oil Check 1 Position the vehicle on a level sur face 2 Remove the propshaft shield from the right side of the vehicle to access the fill plug Remove the fill plug 3 Check the oil level Add oil as needed Do not overfill 4 Reinstall the fill plug Torque to specification Fill Plug 68 MAINTENANCE Transmission Oil Oil Change l 2 9o m ug MD EE Position the vehicle on a level surface Remove the propshaft shield from the right side of the vehicle to access the fill plug Remove the fill plug Remove the transmission drain plug located on the bottom left hand side and drain the oil into an appropriate container Discard used oil properly Clean and reinstall the drain plug Torque to specification Add the proper amount of the recommended lubricant Reinstall the fill plug Torque to specification
22. 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 63 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 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 65 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
23. 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 ATV 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 temperature inside the clutch cover greatly extends the life of the PVT components belt cover etc Tip Avoid heavy pulling and extended low speed operation 94 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 l 2 3 Move the vehicle out of the water Remove the PVT drain plug Allow the water to drain completely Reinstall the drain plug 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
24. 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 104 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 occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 102 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 s
25. 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 37 110 Engine Doesn t Turn Over Possible Cause Tripped circuit breaker TROUBLESHOOTING Solution Reset the breaker Low battery voltage Recharge the battery to 12 8 VDC Loose battery 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 is present in fuel Drain the fuel system 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 a
26. 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 shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers
27. 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 Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 34 Always exercise extreme caution whenever handling gasoline 2 Check the oil level on the dipstick See page 64 Add oil if neces sary to maintain the level in the safe operating range 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 40 6 Pull only light loads 7 Change both the oil and the filter at 20 hours or one month which ever comes first PVT Break in Clutches Belt A proper break 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
28. service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water 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 OPERATION Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the opera tion of this off road vehicle in your area Respect the environment in which you ride Find out where the designated riding areas are by con tacting your Polaris dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 39 OPERATION Pre Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspec
29. 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 63 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 67 Then stop the engine and inspect for leaks 16 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 17 Discard used oil and filter properly 66 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 67 MAINTENANCE Transmission Oil Always check and
30. the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed then shift the trans mission into forward gear Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 95 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 quantities 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 ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always ke
31. to be used as a backup for the main brake sys tem Should the main system fail use the auxiliary foot brake 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 Auxiliary brake the rear wheels without Foot Brake skidding 31 FEATURES AND CONTROLS Brake Fluid AWARNING 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 Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always 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 109 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
32. whenever the cover is loosened or removed Do not overfill 32 FEATURES AND CONTROLS 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 s mr es master cylinder Do not overfill mmmmm 3p 1 Position the vehicle on a level CER surface Make sure the han Indicator dlebars are straight Window 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 Auxiliary Foot Brake Check the brake fluid level frequently for the auxiliary brake system The brake fluid reservoir is located either under the seat or near the foot brake Maintain the fluid level between the minimum and maximum marks Do not overfill 33 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine start a j TOOP ing procedure on page 41 for cor rect choke and throttle settings during starting Fuel Tank Cap 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
33. your dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 113 SPECIFICATIONS Scrambler 500 4X4 Maximum Weight Capacity 275 Ibs 125 kg includes weight of opera tor cargo and accessories Dry Weight 566 lbs 257 kg Fuel Capacity 4 gal 15 1 1 Engine Oil Capacity 2 qts 1 9 1 Transmission Oil 32 oz 946 ml Demand Drive Fluid Capacity 9 oz 265 ml Coolant 2 25 qts 2 131 Rear Rack Capacity Accessory 60 Ibs 27 2 kg Maximum Hitch Tongue Weight Capacity 85 Ibs 38 6 kg Rear rack capacity 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 45 in 114 cm Overall Height 49 in 124 5 cm Wheelbase 48 5 in 123 cm Ground Clearance 4 75 in 12 cm Minimum Turning Radius 65 in 165 cm unloaded Engine Model Number Type EHSOPLE 129 4 Cycle Single Cylinder Lubrication Dry sump Engine Cooling Liquid Displacement 498 cc Bore x Stroke 92 x 75 Alternator Output 250w 5000 rpm Compression Ratio 10 2 1 Carburetor BST 40 Pilot Jet 37 5 Main Jet 155 Needle Jet X 6M Jet Needle 6MGHI 194 4 Pilot Air Jet 1 3 Pilot Screw 3 turns I
34. 2M 1000 1600 Inspect gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc E Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts E Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrestor 300 H 36M 3000 4800 Clean out Idle speed Adjust as needed E Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed 60 Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 57 Items not listed in the chart should be lubricated at the General Lubrication interval See page 109 for the part numbers of Polaris products MAINTENANCE The a arms and lower control arms are lubricated at the factory and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Front Gearcase Premium Fluid Item Lube Method Engine Oil PS 4 PLUS Performance See page 63 Synthetic 2W 50 Brake Fluid DOT 4 Only See page 32 Drive Chain s O ring chain lube or SAE Lubricate 80 90 Transmission Oil AGL Synthetic Gearcase See page 68 Lube Demand Drive
35. 46 1800 amp above 25 48 Blue Green Black 40 6000 amp above 5632408 7041157 7041782 51 ae 115 DECLARATION OF CONFORMITY Polaris Industries Inc 2100 Hwy 55 Medina MN 55340 U S A Telephone 763 542 0500 We Polaris Industries Inc declare that the vehicles listed below conform to the essential health and safety requirements applicable to off road all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 98 37 EC as amended Machinery Directive EN 1050 hazard analysis CD 77 311 EEC driver perceived noise level 2004 108 EC as amended EMC Directive CISPR 12 2001 CAN CSA C108 4 M92 EN 55012 2002 EN 61000 6 2 2001 PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAME MODEL SOUND YEARS PRESSURE dB A KA05 OUTLAW 50 2008 2009 2010 76 8 KAO OUTLAW 90 2008 2009 2010 76 8 FA09 SPORTSMAN 90 2008 2009 2010 76 8 O VAI RZR 170 2009 2010 81 3 PB20 __ PHOENIX 200 2008 2009 2010 76 8 BA32 TRAIL BLAZER 330 2008 2009 2010 76 8 CA3 TRAIL BOSS 330 2008 2009 2010 76 8 BAS0 SCRAMBLER 500 2008 2009 2010 79 6 GM5 OUTLAW 450 2008 2009 2010 80 7 GJS2 GP52 OUTLAW 525 2008 2009 2010 80 7 OLH27 SPORTSMAN 300 2008 2009 2010 81 1 LH46 SPORTSMAN 400 2008 2009 2010 802 MN50 SPORTSMAN 500 EFI 2008 2009 2010
36. INTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 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 approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible 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 72 MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear
37. NDOX volore ue v ee VERMES SPA NAE 127 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 A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV wit
38. STRUCTIONS AND WARNINGS For your nearest Polaris dealer 2d Wm m 1 cal 1 800 POLARIS Uo oy em or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922461 Rev 02 Printed in USA WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs e RANGER utility vehicles Victory Motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sorie
39. Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension Accessory springs are avail able through your Polaris dealer 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 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth several times 3 Tighten the lock nut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 73 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference 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 1 Remove the handlebar cover to Handlebar Bolts access the handlebar bolts Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height 4 Besure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 5 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the re
40. TV due to fire explosions or any other cause beyond Polaris control Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time 118 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imp
41. a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 45 OPERATION Driving Uphill 25 Maximum 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 Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 239g Se t NS 46 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 l Uh Gm Ss Slow down Avoid crossing the side of a steep hill Shift body weight uphill Keep your feet on the footrests If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 47 OPERATION Driving Downhill
42. ake the adjustment 25 ft 7 6 m 1 Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in neutral 3 Lock the parking brake Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring 5 Start the engine Turn the headlight on 6 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Loosen the pivot bolt and adjust the beam to the desired position 8 Tighten the bolt and torque to 60 in Ibs 7 Nm 86 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 leaves 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 so
43. ake 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 109 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery Mark fluid level often Maintain the fluid MIS A level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 99 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 97 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 specific grav ity to 1 270 or greater 3 Reinstall the battery See page 98 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 maintainin
44. al 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 Onconventional 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 if equipped Secure the battery hold down strap O 9 e Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 10 Reinstall the seat 98 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 m
45. amage We rec ommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of USFS standard 5100 1c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 120 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be re
46. ar two bolts A gap of up to 1 8 3 mm will remain at the rear bolts 74 MAINTENANCE Tires AWARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death 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 114 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm when tread depth is worn to 1 8 3 mm or less CD NS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer 75 MAINTENANCE Tires Wheel Removal 1 Position the vehicle on a level surface Place the transmission in gear Lock the parking brake 2 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your Polaris dealer 3 Place a suitable stand under the footrest frame to raise the wheel slightly off the ground Q9 4 Remove the wheel nuts 5 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 poin
47. cket 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 87 MAINTENANCE Lights Taillight Brakelight Lamp Replacement l 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 ens proper operation Reinstall the gasket and lens cover Indicator Lamp Replacement l 2 88 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 Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 114 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Plug Condition Torqu
48. ction When the rear wheels regain traction the demand drive unit will auto matically disengage There is no limit to the length of time the vehicle may remain in AWD Tip The override switch allows activation of AWD in reverse if the AWD switch is on Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 36 OPERATION Failure to operate the ATV properly can result in a collision 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 ATV is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action
49. e Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Turn the fuel valve off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 11 SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the ris
50. e Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft lbs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 90 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Inspect the electrodes for wear and carbon buildup Replace SN worn or fouled plugs Verify that the gap 1s at specification before lt i oe ea installation 4 Reverse the procedure for spark plug installation Torque to specification 89 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
51. e the headlight switch to turn the lights on and off The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights All Wheel Drive Switch See page 36 for all wheel drive information 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 27 FEATURES AND CONTROLS Throttle Lever AWARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident Never start or operate an ATV that has a sticking or improperly operating throttle Always contact your dealer for service before operating the vehicle Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle
52. e 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 Possible Rich Fuel Cause Overuse of choke See your dealer Solution Inspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your dealer 112 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 Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plugs 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 plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See
53. ed States you can enroll in the ATV RiderCourse for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a Polaris ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehi cle are thoroughly inspected at specific intervals FOR MORE INFORMATION ABOUT ATV SAFETY in the United States call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury Eye Protection Long Sleeves Helmet Gloves Long Pants Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards 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
54. ed 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 The vehicle compliance labels can be found on the frame tubing of the vehicle 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 56 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 125 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 vehicle speed of approximately 10 miles per hour 16 km h Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Defini
55. eels on the downhill side Turn the fuel valve off 53 OPERATION Hauling Cargo AWARNING 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 When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Carrying a load high on the rack 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 brak
56. ehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuelsystem Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emis sions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings e Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 123 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI
57. 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 90 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 2 3 10 11 12 Move the vehicle out of the water mad au Turn the fuel valve off Check the air box If water is present dry the air box and replace the filter with a new filter Remove the spark plug Loosen the carburetor drain screw and drain the carburetor Turn the engine over several times using the electric start Dry the spark plug Reinstall the plug or install a new plug Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If neces sary repeat the drying procedure Drain Screw Take the ATV to your dealer for ser vice as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 95 for drying out the PVT 91 MAINTENANCE Spark Arrestor AWARNING Failure to heed the following warnings while servicing the spark a
58. ep 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 96 MAINTENANCE Battery Battery Removal Place the transmission in gear Lock the parking brake Remove the seat Disconnect the battery hold down strap Remove the battery cover if equipped 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 ATV Be careful not to tip a conventional 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 2000 SIRO Uv dq oue eas 97 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 100 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With convention
59. er hose from the engine rss 2 Inspect the filter for debris lt A wo Blow gently through the filter in A Breather Filter PE the direction of the arrow to check for clogging Replace if 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 79 MAINTENANCE Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient opera tion Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C Tip Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting the ATV for conditio
60. er may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items Wheel bearings Electrical components wiring Radiator Switches and controls Transmission seals Cab and body panels Brakes 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 Avoid the use of automotive products some of which can scratch the finish of your vehicle 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 103 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
61. erfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY 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
62. es for travel ing down hills as described in the owner s manual NOTE A special technique is required when braking while traveling down hill See page 48 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides 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 hillside is unavoidable always follow proper procedures as described in the owner s manual See page 47 Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 49 15 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn If all forward speed is lost Always maintain a steady speed when climbing a hill Keep body weight uphill Apply the single lever brake gradually Lock the parking brake when fully stopped Dismount on uphill side or to either side if ATV is
63. es 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 NEVER CARRY CARGO ON THE FRONT OF THE VEHICLE 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 54 OPERATION Hauling Cargo Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual Always read and understand the load distribution warnings on the rack and hitch warning labels Never carry cargo on the front of the vehicle Cargo should be evenly distributed and mounted as low as possible on the rear rack When operating over rough or hilly terrain reduce speed and cargo or towed load to maintain stable driving conditions Towing Loads Always attach a towed load to the hitch point Remove the hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator accessories cargo and weight on hitch must
64. g 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 for recharging 100 Battery MAINTENANCE Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 10096 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75926 10096 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 5096 7596 12 0 12 5 volts 2596 5096 11 5 12 0 volts Needs charge
65. gnition System CDI Ignition Timing 30 2 5000 RPM Idle RPM 1350 Spark Plug Gap BKR6E 036 in 9 mm Based on EU Directive 76 432 EC 114 SPECIFICATIONS Scrambler 500 4X4 Driving System Type Automatic PVT Polaris Variable Transmission Shift Type Side Lever F N R Gear Reduction Reverse 4 74 1 Gear Reduction Forward 3 06 1 Drive Ratio Front 3 818 1 Drive Ratio Final 2 77 1 Drive Chain 520 O Ring Tires Pressure Front 23 x 7 10 4 psi 27 6 kPa Tires Pressure Rear 22 x 11 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 CAM Brakes Front and Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight Single Beam 60w Taillights 12V 8 26W Brake Light 12V 26 9W Battery 12V 14AH Indicators High Temp Neutral Reverse Jetting Chart ALTITUDE AMBIENT TEMPERATURE Meters reel 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 25 52 Blue Green Black 40 0 6000 5632409 7041157 7041782 51 3 l 4
66. grees 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 23 SAFETY Safety Labels and Locations Tire Pressure Load Warning pu cz Age 16 Warning La No Passenger Warning Clutch Cover Warning No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 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 Maximum weight capacity 275 Ibs 125 kg 7175443 24 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 Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7172563 Reverse Override Warn
67. hen operating on unfamiliar terrain Always be alert to changing terrain conditions 17 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 52 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always maintain proper tire pressure as described in the owner s manual and on safety labels 18 SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 51 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating T
68. hout proper instruction Take a training course This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course 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 An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost CC HH Key Number Vehicle Model Number Frame VIN Engine Serial Number right front side of engine crankcase Key Number SAFETY Safety Training ATV safety training is a top priority for Polaris Polaris strongly encourages you and any family members who will be riding the ATV to take a training course If you purchased a new Polaris ATV in the United States your dealer provided instruction to you about the authorized ATV RiderCourse that is available to you and your eligible family members This training is included in the purchase price of your ATV You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV in the Unit
69. hrough Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 50 Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads 19 SAFETY Safety Warnings Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater dis tance for braking Always follow the instructions in the owner s manual for carrying cargo or pull ing a trailer Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water Poor Visibility Operating the ATV in darkness o
70. ible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 122 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle Polaris Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applica ble U S Environmental Protection Agency emission regulations Polaris warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of 500 hours of engine operation 5000 kilo meters 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the v
71. ing 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 4X4 Caution CAUTION Do not push switch to engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage 7175485 25 FEATURES AND CONTROLS Switches Headlight All oe Switch Stop Switch Override Main Key Switch 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 Lr TJ quickly The engine will not start or run N when the switch is off OFE 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 41 for starting pro cedures 26 FEATURES AND CONTROLS Switches Headlight Switch Us
72. ing the break in period 37 OPERATION Safe Operation Practices l 2 10 11 12 13 14 38 Complete the recommended safety 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 ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Before operating learn how to use the auxiliary brake for emer gency situations if service brakes become inoperable Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads 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 an ATV Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged ATV After any overturn or accident have a qualified
73. ithin ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 117 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS 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 ATV that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages 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 or defects in parts components or the A
74. justments Rear 73 Starting the Engine 41 42 Steering Assembly 73 Storage ssi neu S sa od 102 107 Switches AWD Switch 27 36 Engine Stop Switch 26 Headlight Switch 27 Main Key Switch 26 T Throttle Cable Freeplay 73 Throttle Lever 0 28 Tire Tread Depth 75 TILES E 75 77 Front Wheel Hub Tightening 75 Tread Depth 75 Wheel Installation 76 Wheel Nut Torque 77 Wheel Removal 76 Toe Alignment 72 T Towing Loads 55 Trail Etiquette 0 0000 39 Trainings ics ea kek eared on ees 7 Transmission Oil 68 69 Transmission Oil Recommendations 68 Transporting the Vehicle 108 Tread Lightly 39 Turning Around ona Hill 49 Turning the Vehicle 44 V Vehicle Identification Numbers 6 Vehicle Immersion 91 Ww Warning Symbols 4 Washing the Vehicle 102 103 Wheel Hub Tightening 75 Wheel Installation 76 Wheel Nut Torque Specifications 77 Wheel Removal 76 129
75. k of a serious injuries in the event of an accident Operator and passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV Carrying a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV 12 SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the ATV and could result in loss of control and accident or overturn Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s risk of losing control Alway
76. king 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 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 the knob is pulled completely out Knob The choke is off when the knob is pushed completely in The choke a ea can be adjusted gradually depend Adjustin ing on how much choke 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 41 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 42 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 atte
77. lack 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 ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications 3 16 3 8 5 mm 10 mm Use the following procedure if adjustment is required l 2 3 82 Remove the chain guard Loosen the chain guide Pin Punch EF rn eccentric ocking bolts TE Loosen the caliper mounting Q 1 bolt located on the left side of the swing arm Locking Bolts Insert a pin punch through the sprocket hub and into the eccentric housing MAINTENANCE Drive Chain Rear Drive Chain Slack 6 Roll the ATV forward or backward to adjust the chain slack to the proper tension See the illustration for proper splice link clip opening position 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 Position 8 Tighten the caliper mount bolt to 15 ft Ibs 20 Nm 9 Remove the pin punch 10 Roll the ATV 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
78. maintain replace or repair the emission con trol devices or systems on your vehicle Polaris recommends that you contact an autho rized Polaris dealer to perform any service that may be necessary for your vehicle Polaris also recommends that you use only Pure Polaris parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the Polaris Warranty Department at 1 888 704 5290 124 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 125 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 126 A Air Filter 02 002 000 78 All Wheel Drive Switch 27 36 All Wheel Drive System 36 B Battery 2 0 cece eee eee 96 101 Charging Conventional 100 Charging Sealed 100 101 Fluid Conventional 99 Installation 98 R m
79. minimum and maximum marks on the bottle when the fluid is cool 2 Add coolant as needed Recovery Bottle 84 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair 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 Radiator Cap Remove the pressure cap 3 Ifcoolant is low use a funnel and slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pressure 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 85 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to m
80. mpting 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 engine idles smoothly push the choke completely in OPERATION Driving Procedures x 9o ON ee Wear a helmet and eye protection See page 8 Sit upright with both feet on the footrests and both hands on the handlebars 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 parking brake Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 43 OPERATION Turning the Vehicle Your ATV is equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the
81. nd 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 Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Exhaust leaks Replace exhaust seals 111 TROUBLESHOOTING Engine Pings or Knocks 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 or defective spark plugs 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 Se
82. ne Solution Use low range if equipped or turn around using the K turn see page 49 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 Climbing 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 95 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
83. ng Brake 1 Place the transmission in gear e 2 Squeeze and release the brake lever two or three EET times then squeeze and H Ale 3 Push the parking brake lock X hold forward to engage the lock 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 WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before 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 ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling Ei i le 30 FEATURES AND CONTROLS Auxiliary Foot Brake AWARNING Aggressively applying the auxiliary 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 system is intended
84. not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum hitch weight capacity can result in serious damage to the vehicle and will void your ATV warranty Always install Polaris approved or equivalent accessories designed for ATV use 55 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system 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 maintain
85. ns in your area Carburetor Engine Idle RPM Adjustment If the engine idle speed is not satisfac tory and all other conditions are favor PSE Ges able the carburetor can be adjusted See 1 Place the transmission in gear Lock the parking brake 2 Start the engine and allow it to warm up for approximately five minutes 3 Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM Adjuster 80 MAINTENANCE Drive Chain Drive Chain Lubrication Polaris ATV drive chains are equipped with o ring sealed permanently greased pins and rollers However the outer surfaces of the roller must be lubricated Always inspect the drive chain prior to operating the vehicle Check for damaged or missing o rings or 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 109 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 81 MAINTENANCE Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain s
86. oval oi eis erre 97 Storage crus cus ace E EUER 99 BOOtSics ERE 9 Brake Fluid 32 33 Brake Inspections 71 Brake Lever 00005 29 Brake Foot 0 0005 31 Brake Parking 30 Brakes ice eae ka eat 71 Break In Period 37 Breather Filter 79 C Camber Adjustment 73 Carburetor 000 80 Carburetor Adjustment 80 afgOss iuo Sack edu eerie 54 55 Caster Adjustment 73 Chokes aee della Plates 34 Chrome Wheel Care 104 Cleaning and Storage 102 107 Clothing 7 3024 voters cx 9 Clutching Chart 115 Consumer Product Safety 7 Coolant Bottle 84 Coolant Radiator 85 Cooling System 84 85 Corrosion Removal Chrome 104 Crankcase Emission Control System 56 D Demand Drive Fluid 70 Drive Belt Wear Burn 110 Drive Chain 81 83 Drive Chain Lubrication 81 Drive Chain Slack 82 83 Drivetrain Break In 37 Driving Downhill 48 Driving in Reverse 52 Driving on a Sidehill 47 Driving on Slippery Surfaces 45 Driving Over Obstacles 51 Driving Procedures 43 Driving Through Water 50 Driving Uphill suus 46 E Electromagnetic Interference
87. pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 49 If the ATV begins rolling downhill Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees Keep body weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 49 16 SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution w
88. quested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 121 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be elig
89. r air 50H 6M 500 800 Inspect duct for proper seal intake ducts flange ing air leaks Drive belt 50H 6M 500 800 Inspect adjust replace as needed Cooling system 50H 6M 1000 1600 Inspect coolant strength if applicable seasonally pressure test system yearly gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at 20 hours gt Oil filter change 100 H 6M 1000 1600 Replace with oil change P Oil tank vent hose 100 H 12M 1000 1600 Inspect routing condition if equipped Valve clearance 100 H 12M 1000 1600 Inspect adjust E Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service W Have an authorized Polaris dealer perform these services 59 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Radiator 100 H 12M 1000 1600 Inspect clean external if applicable surfaces gt Cooling hoses 100 H 12M 1000 1600 Inspect for leaks if applicable gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe E Spark plug 100 H 12M 1000 1600 Inspect replace as needed E Ignition Timing 100 H 1
90. r inclement weather could result in a collision or accident especially if operating on a road or street This ATV is not equipped with highway approved lights Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 20 SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Physical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 21 SAFETY Safety Labels and
91. 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 I 14 17 ft Ibs 19 23 Nm Synthetic 2W 50 4 Cycle Oil 63 MAINTENANCE Engine Oil Oil Level The oil dipstick is located on the left side of the vehicle l 64 Position the vehicle on a level surface Place the transmission in neutral Lock the parking brake Start the engine Allow it to idle for 30 seconds Stop the engine Remove the dipstick Wipe it dry with a clean cloth Reinstall the dipstick completely Make sure the cap is fully seated to keep the angle and depth of the stick consistent Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Reinstall the dipstick Safe Range C Add Oil Safe MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 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
92. rrestor 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 Ty 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 throttle 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 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 92 MAINTENANCE PVT Sys
93. s available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS THE WAY OUT and SCRAMBLER are registered trademarks of Polaris Industries Inc Copyright 2009 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 U S A 2010 Scrambler 4X4 Owner s Manual P N 9922461 2 TABLE OF CONTENTS Introduction i uivsum LRL YA eLERELZe5ERRPS 4 Safety sois riu V ee SSS eR Eee Ot oes 7 Features and Controls 26 Operation si rakuna EUER ER 37 Emission Control Systems 56 Maintenance s sees 57 Polaris Products Ls 109 Troubleshooting e 110 Specifications cvv err rrr 114 Declaration of Conformity 116 Warranty fie cxi rub GR eee es 117 Maintenance Log 000ee0es 125 I
94. s operate at a speed that s appropriate for the terrain the visibility and operating conditions and your experience 13 SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 46 14 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedur
95. t the ATV before each use to make sure it s in safe operating condition Item Remarks Page Brake system lever travel Ensure proper operation zs Brake fluid Ensure proper level 32 Auxiliary brake Ensure proper operation 31 Front suspension Inspect lubricate if necessary 61 Rear suspension Inspect lubricate if necessary 61 Steering Ensure free operation Tires Inspect condition and pressure 75 Wheels fasteners Inspect ensure fastener tightness 75 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels E Coolant level Ensure proper level 84 Coolant hoses Inspect for leaks Throttle Ensure proper operation 2 Indicator lights switches Ensure operation 26 Engine stop switch Ensure proper operation 26 Drive chain Check condition slack lubricate as 81 needed Air filter pre filter Inspect clean 78 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 27 tric grease when lamp is replaced 87 Brake light tail lamp Check operation apply Polaris dielec 88 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 8 protective clothing 40 OPERATION Starting the Engine 1 2 3 Tip 4 5 Tip 6 Tip Position the vehicle on a level surface outdoors or in a well venti lated area Place the transmission in neutral Lock the par
96. tem 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 Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 93 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
97. ting toward forward rotation 2 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 3 Lower the vehicle to the ground Torque the wheel nuts to specification page 77 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 76 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 77 MAINTENANCE Air Filter 1 Remove the seat Pre Filter 2 Release the air box cover clips and remove the air box cover Main Filter 3 Loosen the clamp and remove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main fil ter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur 7 Reinstall the air box cover and the seat 78 MAINTENANCE Breather Filter 1 Remove the clamps and pull the breather filter out of the hoses It s not necessary to remove the low
98. tion Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle 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 57 MAINTENANCE Periodic Maintenance Chart AWARNING Improperly performing the procedures marked with a I 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 E severe use Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km W Steering Pre Ride Make e ele need 7 7 ed See Pre Ride Checklist gt Front suspension Pre Ride on page 40 gt Rear suspension Pre Ride Tires Pre Ride
99. ttom of the footrests Follow these pro cedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines 3 Avoid operating through deep or fast flowing water NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 57 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 91 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads Maximum Depth If it s unavoidable to enter water deeper than the footrest level 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 50 OPERATION Driving Over Obstacles
100. 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 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 57 Battery Storage See pages 99 100 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover Do not use plastic or coated mate rials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 107 MAINTENANCE Transporting the Vehicle Follow these procedures when lt transporting the vehicle p 3 fj 1 Stop the engine N 2 Place the transmission in gear H 3 Lock the parking brake 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 te the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 108 Part POLARIS PRODUCTS
101. ystems 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 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 65 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 105 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 57 Demand drive unit front gearcase Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine l 106 Treat the fuel system with Polaris Carbon Clean See page 105 Support the front end of the machine so the engine is level or tilted slightly rearward Remove the spark plug Pour 2 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

Polaris 9922461 Offroad Vehicle User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents