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Polaris 9921123 Offroad Vehicle User Manual

1. 5 Safety 2 Viet 6 Features and Controls 31 Operation s 41 Emission Control Systems 59 Maintenance 60 lt 108 Polaris Products 111 Troubleshooting 112 Warranty 116 Maintenance Log 118 INGOX aus sixki E ERE VENE MEE 121 KNOW YOUR VEHICLE As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Ride responsibly Know all laws and regulations concerning the operation of this vehicle in your area 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 Vehicle Model Number Frame VIN 1 Engine Serial Number right front side of engine crankcase Key Number 2 SAFETY Operator Safety
2. the dipstick see page 1 66 Add the recommended oil as needed to maintain the oil level in the normal operating range 1 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary 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 42 6 Pull only light loads 7 During the break in period change both the oil and the filter at 25 hours or one month whichever 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 during the break in period 41 OPERATION Pre Ride Inspection 4 WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Pre Ride Checklist Brake system lever travel Brake fluid Auxiliary brake Ensure proper operation Ensure proper level Ensure proper operation Inspect lubricate if necessary Inspect lubricate if necessary Front suspension Rear suspension Steering Tires Ensure free operation n
3. Locking the Parking Brake 1 Squeeze and release the brake lever two or 1 three times then squeeze and hold 2 Push the parking brake lock 1 forward to engage the brake Release the brake lever 3 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards The parking brake may relax if left on for a long period of time AI ways block the wheels to prevent rolling Always block the wheels on the downhill side of the vehicle if leav ing it parked on a hill Another option is to park the vehicle in a sidehill position Never depend on the parking brake alone if the vehicle is parked on a hill Always block the wheels to prevent rolling 36 FEATURES AND CONTROLS Auxiliary Brake 4 amp WARNING Aggressively applying the rear brake when backing downhill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary foot brake 1 is located on the inside of the right floorboard and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal p
4. Pantone 425 C CD CED CED QD GCD CP CS Pantone 425 C Before you operate this vehicle read the owner s manual Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehiculo lea el Manual del Propietario Lire le manuel du propri taire avant d utiliser ce v hicule Prima di usare il veicolo leggete il manuale di istruzioni Lue aina k ytt ohjekirja ennen taman ajoneuvon k ytt Antes de utilizar este ve culo leia o manual do propriet rio Innan du k r detta fordon l s handboken 7173025 PELARIS For your nearest Polaris dealer The Way Out visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 U S A Part No 9921620 Rev 01 Printed in U S A WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs Quadricycles RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructi
5. 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 Run the engine for two to three minutes then turn it off 3 Place a drain pan beneath the oil tank and remove the drain plug 1 Allow the oil to drain completely 4 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank 3 NOTE The fitting threads should be clean and free of burrs nicks or scratches Reinstall the drain plug and torque to 14 17 ft Ibs 19 23 Nm Disconnect the lower oil delivery hose and remove the screen fitting 3 from the oil tank Clean the fitting must be sealed with LOCTITE PST 505 or PTFE seal tape Reinstall the screen fitting and rotate the fitting clockwise 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 4 on the tank NOTE Do not over tighten Maximum torque for the screen fitting is 8 25 ft Ibs 34 Nm Reattach the oil line 67 MAINTENANCE Engine Oil Oil and Filter Change 9 10 11 12 NOTE The sealing surfaces on 13 14 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter 1 counterclockwise and remove Lubricate the gasket on the new filter with a film of new engine oil Check to make sure the gasket is in goo
6. Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads 4 WARNING POTENTIAL HAZARD Operating this Quadricycle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the Quadricycle with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the vehicle Always maintain proper tire pressure as specified 23 SAFETY Operator Safety 4 WARNING 24 POTENTIAL HAZARD Operating the Quadricycle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the Quadricycle may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the Quadricycle through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this Quadricycle and should be installed and used according to approved instructions See your authorized Polaris Quadricycle dealer for more information WARNING POTENTIAL HAZARD Overloading the Quadricycle or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZAR
7. The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety 4 WARNING Failure to follow the warnings contained in this manual can result in serious injury or death A Polaris Quadricycle is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or 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 and understand your owner s manual and all warnings before operating a Polaris Quadricycle Safety Training When you purchased your new Quadricycle your dealer offered a hands on safety training course You were also provided with printed materials that explain
8. exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DE SCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE Some states do not permit the exclusion or limitation of incidental or consequen tial damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 116 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES 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 to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris Quadricycles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANS PORTATION T
9. 1000 1600 Inspect routing condition Valve clearance 100 H 1000 1600 Inspect adjust Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines 2M Cooling system every two years Radiator 100 H 1 1000 1600 Inspect clean external if applicable surfaces 62 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Cooling hoses 100 H 12M 1000 1600 Inspect for leaks if applicable 100011600 Exhaust muffler 100 H 12M 1000 1600 Inspect pipe H Spark plug 100 H 1000 1600 Inspect replace as needed 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings 5000 4800 Wesel Toe adjustment EE Inspect periodically adjust when parts are replaced Fr ede J p Perform these procedures more often for vehicles subjected to severe use Emission Related Service m Have an authorized Polaris dealer perform these services i i Wiring Ll L m Headlight aim 63 MAINTENANCE Lubrication Recommendations Always check and change fluids and lubricate greaseable components at the intervals outlined in
10. CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides Stability and maneuver ability may be adversely affected causing the machine to over turn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry ing loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass 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 47 OPERATION Driving Safely Making Turns Your Polaris vehicle is equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To make a 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 NOTE Practice making turns at slow speeds before attempting to turn at faster speeds 4 WARNING Turning
11. To stop the engine slide the stop switch either right or left to the OFF position NOTE Turning off the engine stop switch will shut off all electrical power to the vehicle including the lights 31 FEATURES AND CONTROLS Light Switches The light switch is located on the left handlebar 1 It s used to turn the lights on and off and to switch the lights from high beam to low beam E lege NOTE The lights won t work unless the key is in the ON position and the shut off switch is in the RUN position Indicator Lights With the engine running verify the function of all indicator lights each time the vehicle is used NOTE The taillight is on whenever the main switch key is on Turn the key off to prevent battery drain E RA 1 Transmission Neutral Indicator 2 Transmission Reverse Indicator 3 High Temp Warning displays if engine overheats 32 FEATURES AND CONTROLS Throttle Lever A WARNING Do not start or operate a Quadricycle with sticking or improperly operating throttle controls which could cause an accident and lead to severe injury or death Always contact your dealer for service repairs if throttle problems arise 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 oper
12. 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 plier 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 87 MAINTENANCE Filter Systems Air Filter Service 1 Remove the seat release 1 the clips and remove the 2 air box cover C Loosen the clamp and remove the filter 3 Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water then rinse and let dry 4 Reinstall the pre filter over the main filter Replace the main filter if needed 5 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Breather Filter Hose CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service 1 Remove the clamps and pull the filter 1 out of the hoses NOTE It s not necessary to remove the lower hose from the engine 2 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if needed 3 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 4 Reinstall the filter and secure the clamps N
13. becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Discretionary Warning 1 WARNING 1 Never operate this vehicle on LG HILLS steeper than 25 degrees 2 25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle PARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in forward Clutch Cover Warning 2 WARNING NO STEP 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 im and excessive engine RPM which can result in serious injury or eath 27 SAFETY Safety Decals and Locations General Warning 3 Poe 3 WARNING ork 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 at speed
14. reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE This Polaris vehicle is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed CAUTION 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 57 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 1 2 3 58 Turn the engine off Place the transmission in gear Lock the parking brake Always block the rear wheels on the downhill side See illustration Shut off the fuel supply EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with governmental noise level requirements Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be main
15. the Periodic Maintenance Chart beginning on page 60 Items not listed in the chart should be lubricated at the General Lubrication interval NOTE 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 Lubrication Chart Key gt More often under severe use such as wet or dusty conditions Polaris Premium All Season Grease or grease conforming to NLG No 2 such as Conoco Superlube M or Mobilegrease Special e Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging A When suspension action becomes stiff or after washing Engine Oil PS 4 PLUS Performance Add to proper level on dipstick Synthetic 2W 50 Brakes DOT 4 fluid only Maintain level between fill lines See page 35 Drive chain s O ring chain lube or SAE Lubricate 80 90 1 Transmission AGL Synthetic Maintain as recommended on Gearcase Lube page 70 2 Swing Arm Bush px Grease Locate fittings on swing arm and ings grease with grease gun 3 Tie Rod Ends PXA Grease Lift boot clean away dirt and grease apply fresh grease by hand and reassemble 4 Axle Housing px Grease Locate fittings on swing arm and grease with grease gun 64 MAINTENANCE Lubrication Recommendations 65 MA
16. the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the footrest frame Remove the wheel nuts and remove the wheel 79 MAINTENANCE Wheels Wheel Installation 1 Place the transmission in gear and lock the parking brake 4 WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 2 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten On vehicles with tapered rear wheel nuts make sure the tapered ends of the nuts fit into the tapers on the wheels 4 Lower the vehicle to the ground 5 Torque the nuts to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance Item Specification Front Wheel Nuts 27 ft lbs 37 Nm Rear Wheel Nuts 50 ft Ibs 68 Nm Front 27 ft Ibs 37 Nm 80 MAINTENANCE Wheels Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer Tire Tread Depth Always replace tires when tread dept
17. ve doles ote dae 78 CHOKE ape 38 Chrome Wheel Care 104 Cleaning and Storage 102 107 Clutch 41 Coolant Level 84 Cooling System 84 85 D Drive Chain 72 Drivetrain Break in 41 Driving Downhill 53 Driving in Reverse 57 Driving on Slippery Surfaces 49 Driving Over Obstacles 56 Driving Procedures 45 Driving 45 58 Driving Through Water 55 Driving Uphill 51 52 E Electrical Switches 31 Engine Break in 41 Engine Cooling System 84 85 Engine Fogging 106 Equipment Modifications 7 Exhaust Emission Control System 59 F Filter Systems 88 Front Wheel Hub Tightening 81 Fuel Filtet a eres 38 Fuel Safety 26 Fuel Stabilizer 105 Fuel Tank 38 Fuel Valves i e 38 G Gear 1 39 H Handlebars 77 Hauling 46 47 Headlight Lamp Replacement 86 High Beam Adjustment 86 l Indicator Lamp Replacement 87 Indicator Lights 32 K aaee eas one 54 L Light Switches 32 Eights meo sd eck od ooo 86 87 Lubrication Reco
18. your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 91 Have the vehicle serviced by your dealer at the first opportunity 55 OPERATION Driving Safely Driving Over Obstacles es B R Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches 4 WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 56 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 Always avoid backing downhill 2 Back slowly 3 When in reverse apply the brakes lightly for stopping 4 Avoid turning at sharp angles in reverse 5 Never open the throttle suddenly while backing 4 WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into
19. 1460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogel 2872073 Chain Lube 6 25 oz aerosol 2872348 Chain Lube 16 oz aerosol Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT 4 Brake Fluid 2871956 LOCTITE 565 Thread Sealant 2871076 Polaris Battery Tender Charger 111 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Drive Belt and Cover Problems Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or low ground speed at approximately 3 7 MPH Insufficient warm up of vehicles exposed to low ambient temperatures Slow easy clutch engage ment Towing pushing at low RPM low ground speed Utility use plowing Stuck in mud or snow Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Shift transmission to low range during loading of the Quadricycle to prevent belt burning When starting out on an incline use low range or dis mount the vehicle after first locking the parking brake and perform the K turn as described on page 54 Drive at a higher speed or use low range more frequent
20. D Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 46 WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the Quadricycle on a frozen body of water SAFETY Operator Safety A A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING 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 which could result in severe injury or death CAUTION Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always k
21. INTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60 Always change the oil filter whenever changing oil Oil Recommendations Polaris recommends the use of Polaris PS 4 PLUS Performance Synthetic 2W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 111 for the part numbers of Polaris products CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Cil Check 1 Position the vehicle on a level surface 2 Start the engine and let it idle for 20 20 seconds Stop the 3 Remove the dipstick 1 which is located on the left side of the vehicle 4 Wipe the dipstick dry with a clean cloth Reinstall it and screw it completely in NOTE The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and read the oil level ADD 8 OZ NORMAL FULL Maintain the oil level in the normal operating 2 range 2 Do not overfill 66 MAINTENANCE Engine Oil Oil and Filter Change 4 CAUTION Contact with hot oil may result in serious burns Do not allow hot oil to come into contact with skin
22. O AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 117 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 118 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 119 120 Age Restrictions 7 Air Filter io stes e aen 88 Auxiliary Brake 37 75 B Battery S im tede RES 95 101 Battery Charging Conventional 99 Battery Charging Sealed 100 101 Battery Fluid Conventional 99 Battery Installation 97 Battery Removal 96 Battery Storage 98 Belt 41 Brake Lever 34 Brake Auxiliary 75 Brakes iu n TU 35 74 75 Break In 41 Breather FilterlHose 88 C Camber and Caster 76 Carburetor io
23. OTE The filter is effective with the arrow pointing in either direction 88 MAINTENANCE Spark Plugs Spark Plug Recommendations CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 108 Refer to the specifications section beginning on page 108 for the recommended spark plug type and gap for your vehicle Torque spark plugs to specification Plug Condition Torque 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 4 WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Remove the spark plug cap Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specification 89 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This in
24. aning 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 accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always maintain brake fluid at an adequate level see page 35 4 WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill NOTE 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 Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper operation Use Polaris DOT 4 brake fluid Do not overfill 74 MAINTENANCE Brakes 1 Check the brake system for fluid leaks 2 Check the brakes for excessive travel or spongy feel 3 Check the friction pads for wear damage and looseness 4 Check security and surface condition of the disc NOTE Pads should be changed when worn to 3 64 1 cm 3 64 1 cm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on th
25. aninto the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 50 OPERATION Driving Safely Driving Uphill 4 WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 51 OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions Always travel straight uphill Avoid steep hills 25 maximum Keep both feet on the footrests Transfer your weight forward Proceed at a steady rate of speed and throttle opening Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle If all forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary brake as well then lock the parking brake DNR eaaet If the vehicle begins rolling backwards Keep your weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwar
26. at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 48 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 3 Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 4 WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 49 OPERATION Driving Safely Sidehilling 4 amp WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Le
27. ation Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded Engine speed returns to idle when the lever is released This vehicle is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 4 WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms 33 FEATURES AND CONTROLS Brake Lever 4 WARNING Operating the vehicle with a spongy brake lever can result in loss of braking which could cause an accident Never operate the vehicle with a spongy feeling brake lever The front and rear brakes are applied by squeezing the brake lever 1 toward the handlebar The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding 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 d
28. ator should be inspected NE and coolant added if necessary I m 1 Remove the front panel to access the E radiator pressure cap 1 Remove the cap 2 Ifcoolant is low use a funnel and slowly add coolant through the radiator filler neck 3 Reinstall the pressure cap and secure the front panel 4 Fill the coolant recovery bottle to the upper mark on the bottle 5 Check the coolant level in the bottle frequently adding coolant as needed until the level stabilizes NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 85 MAINTENANCE Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 4 WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 Remove the wire harness connector from the back of the headlight 2 Grasp the bulb housing and turn it counterclockwise to remove the bulb 3 Apply dielectric grease to the light bulb socket before installing the new bulb Install the replacement bulb int
29. 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 preserve wheel life and ensure a like new appearance for many years NOTE Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each polished 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 outlined above 104 MAINTENANCE Cleaning and Storage Storage Ti
30. ays follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the Quadricycle SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well then lock the parking brake If the Quadricycle begins rolling backwards Keep 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 auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if vehicle is pointed straight uphill Turn the vehicle around and remount following the procedure described in the owner s manual See page 54 21 SAFETY Operator Safety 4 WARNING 22 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees whe
31. bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation f you do not hear air the line has not bled and you ll need to repeat the priming procedure 69 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60 Maintain the oil level within the SAFE operating range on the dipstick We recommend the use of Premium AGL Synthetic Gearcase Lubricant See page 111 for the part numbers of Polaris products Cil Check The transmission oil dipstick 1 is located on the right side of the vehicle 1 Position the vehicle on a level surface 2 Remove the dipstick and wipe it clean 3 Reinstall the dipstick completely then remove it and check the level 4 Add the recommended lubricant to bring the level into the safe operating range 2 5 Reinstall the dipstick 70 MAINTENANCE Transmission Oil Refer to the specifications section beginning on page 108 for transmission oil capacity Oil Change 1 2 8 9 Position the vehicle on a level surface Place a drain pan beneath the transmission oil drain plug area Loosen the jam nut A Turn the adjuster bolt B in to allow the removal of the drain plug C Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings After the oil has drain
32. d condition Also make sure the gasket from the old filter is not still on the engine Install the new filter and tighten by hand 1 2 to 3 4 turn after gasket contacts the engine Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crankcase the drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug and torque to 14 ft Ibs 19 Nm Remove the dipstick 2 and add two quarts 1 9 1 of the recommended oil Reinstall the dipstick NOTE Ifthe sump is not drained add about 1 3 4 quarts initially 15 16 17 18 68 Place the gear selector in neutral Lock the parking brake Prime the oil pump using the procedure on page 69 Then stop the engine and inspect for leaks Recheck the oil level on the dipstick and add oil as necessary to bring it to the recommended level on the dipstick Dispose of used filter and oil properly MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line 1 approximately 2 from the oil tank 2 between the end of the oil tank vent fitting and the vent line s pressure relief slit 3 2 Run the engine for 10 20 seconds 3 Remove the vent line clamp If the line is
33. d fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 115 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not s
34. degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating and engine or PVT damage See your Polaris dealer for more information about jetting the vehicle for conditions in your area If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Warm up the engine by running the vehicle for approximately five minutes 2 Place the transmission in gear and engage the parking brake 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Refer to the specifications section beginning on page 108 for the proper setting NOTE Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM 78 MAINTENANCE Wheels amp WARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your vehicle and in your owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less Wheel Removal 1 Stop the engine place the transmission in gear and lock the parking brake Loosen
35. dicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Recoil Housing To prevent possible engine damage always drain the recoil housing 1 1 after operating the vehicle in very FA wet conditions This should also be S A AN N done before storing the vehicle F 5 Cam SY ALLS 2 Water will enter the recoil housing E if the starter handle is disengaged a 05 _ from the rope guide when under i water The drain screw is located at the bottom of the recoil housing Use a wrench to remove the screw Be sure to reinstall the screw after draining the housing NOTE Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crankcase drain is opened 90 MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the
36. ds Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if vehicle is pointed straight uphill Turn the vehicle around and remount following the procedure described on page 54 52 OPERATION Driving Safely Driving Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing using the single brake ever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss 4 WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 53 OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 54 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to you
37. e battery cable first Disconnect the red positive battery cable next Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte 4 CAUTION 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 Pi RUSY 96 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on pages 99 101 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed batteries do not have a vent tube NOTE 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 4 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 Insta
38. e engine starts If the engine does not start and all conditions are favorable change the spark plug and try again If the engine slows 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 CAUTION Operating the vehicle immediately after could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle OPERATION Driving Safely Driving Procedures 1 Sit upright with both feet on the footrests and both hands on the handlebars 2 Start the engine and allow it to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 45 OPERATION Driving Safely Hauling Cargo 1 3 Accessory racks and hitches are available from your Polaris dealer Always read and understand the load distribution warnings on all warning labels and never exceed the specified weight capacities for the vehicle Maximum Towing Capacities Refer to the specifications at the rear of this manual for towing capacities When towing reduce the rear rack cargo l
39. e handlebars can be adjusted for rider preference 1 2 3 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 possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service Remove the handlebar cover to access the handlebar bolts 1 Loosen the four bolts Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right Torque the two front bolts to 10 12 ft Ibs 14 17 Nm then torque the two rear bolts A gap of up to 1 8 will remain at the rear bolts 77 MAINTENANCE Carburetor IMPORTANT Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4
40. e inside of the right footrest The hydraulic auxiliary brake system requires no adjustment NOTE Since this is a rear brake only it will not be as effective as the all wheel single lever system 75 MAINTENANCE Steering Assembly The steering assembly of the vehicle should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Throttle Cable Freeplay 1 Locate the throttle cable adjuster at the handlebar 2 Squeeze the end of the rubber boot A and slide it far enough to expose the end of the inline cable adjuster B A 3 Loosen the adjuster locknut C 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is B gt achieved at the thumb lever NOTE Move the throttle lever back and forth while adjusting 5 Tighten the locknut i e 6 Reinstall the boot s to their original 1 16 to 1 8 position 1 5 3 mm NOTE Engine RPM should not increase when steering is A turned full left or right Readjust cable freeplay if o this occurs 76 MAINTENANCE Handlebars amp WARNING Th
41. ed completely install a new sealing washer and reinstall the drain plug Torque to 14 ft lbs 19 Nm Turn the adjuster bolt B out until it touches the frame and then turn an additional 1 2 turn Tighten the jam nut securely while holding the adjuster bolt Remove the dipstick Add the recommended lubricant until the oil level is between the upper and lower limits Do not overfill 10 Reinstall the dipstick 11 Check for leaks 71 MAINTENANCE Drive Chain The 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 cm Regularly lubricate the drive chain with Polaris Chain Lube an SAE 80 90 lube or an approved o ring chain spray lube See page 111 for the part numbers of Polaris products CAUTION 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 72 MAINTENANCE Toe Alignment 4 WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod ad
42. ed 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 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 operating 1 2 Remove the drain plug and allow the water to drain Reinstall the drain plug Start the engine and shift the transmission into neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 93 MAINTENANCE Spark Arrestor 4 WARNING 94 Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before
43. eep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass 25 SAFETY Fuel Safety 4 WARNING 26 Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the vehicle is stored or parked WARNING 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 SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection Read and follow the instructions of the decals on the vehicle carefully If any of the decals depicted in this manual differ from the decals on your vehicle always read and follow the instructions of the decals on the vehicle If any decal
44. engine If it s impossible to take your Quadricycle to a dealer before starting it follow the steps outlined below 1 GE 00 c4 9 11 Move the vehicle to dry land or at the very least to water below the footrests Check the airbox for any water Drain and dry it if water is present Turn the fuel valve off Remove the spark plug Turn the engine over several times using the electric start Loosen the carburetor drain screw 1 Dry the spark plug and reinstall or replace it with a new plug Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If necessary repeat the drying procedure Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not NOTE f water has been ingested into the PVT follow the procedure on page 93 for drying out the PVT 91 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 centrifugal force decreases reducing the amount of belt pinch This begins to occur at speeds of less than 5 MPH due to the system s dependence on engine speed For example when ope
45. er 1 Use 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 water may damage components and could remove paint and decals Avoid directing the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals Electrical components and wiring NOTE f warning and safety labels are damaged contact your Polaris dealer for free replacement 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
46. genuine Polaris cover NOTE not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Transporting the Quadricycle Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Turn the fuel valve off 3 Besure the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the Quadricycle to the transporting unit securely using suitable straps or rope See illustration 5 Always place the transmission in gear and lock the parking brake 107 SPECIFICATIONS 2008 Scrambler 500 2X4 International Body Sti Maximum Weight Capacity Fuel Transmission Engine Front Rack Accessory Rear Rack Accessory Hitch Towing Rating Hitch Tongue Weight Capacity 85 Ibs 38 6 kg Tum Radius Ground Clearance Width Seat Height Dry Weight Wheel Base Tet Needle 30 5000 RPM Based on EU Directive 76 432 EC 108 Unbraked Trailer Towing Capacity 1210 165 549 kg Height 47 in 119 4 cm SPECIFICATIONS 2008 Scrambler 500 2X4 International Shit Type Gear Reduction Reverse Gear Reduction Forward Final Drive Drive Chan Front Suspension Mac Strut Rear Suspension Progressive Rate 10 5 in 26 7 cm travel Swing Arm Shock Adjustment Auxiliary Brake Parking Brake Headligh
47. h is worn to 1 8 3 cm or less See illustration 1 8 3 cm x 4 WARNING Operating the vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less 4 WARNING Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Maintain proper tire pressure as outlined in this owner s manual When replacing a tire always use original equipment size and type 81 MAINTENANCE Rear Drive Chain Slack CAUTION Adjusting or operating the vehicle with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain Measure the chain slack at the tightest of the three positions At this point the chain should have 3 16 3 8 48 cm 95 cm deflection Use the following procedure if adjustment is required 3 16 3 8 48 cm 95 cm 1 Remove the chain guard Loosen the chain guide 3 Loosen the two eccentric locking bolts 1 4 Loosen the caliper mounting bolt located on the left side of the swing arm 5 Inser
48. 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 crankcase 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 60 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key p Perform these procedures more frequently for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions m Have an authorized Polaris dealer perform these services 4 WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Calendar Miles Km Make adjustments as need Front Pro Rid ed See Pre Ride Checklist Pees Fee gt pes gt gt gt Bake Taso gt E Air filter pre filter Daily Inspect clean often replace as needed Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years Headlamp tail Da
49. iagnosis and repairs 34 FEATURES AND CONTROLS Brakes Check the brake fluid level in the master cylinder before each use of the vehicle The master cylinder 1 is located on the left handlebar The fluid level can be seen through an indicator window 2 on the top of the master cylinder This will appear dark when the fluid level is full When fluid needs to be added the eye will be clear 4 WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill NOTE When checking the fluid level the vehicle must be on level ground with the handlebars straight If the fluid level is low add DOT 4 brake fluid only DO NOT OVERFILL See page 111 for the part numbers of Polaris products 4 WARNING 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 accident or severe injury After opening a bottle of brake fluid always discard any unused portion 35 FEATURES AND CONTROLS Parking Brake 4 WARNING Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating
50. igned the original registration and received the customer copy please contact your dealer immediately NO WAR RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in ma terial or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any Quadricycle that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any dam ages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polar is control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the Quadricycle The exclusive remedy for breach of this warran ty shall be at Polaris
51. ily Check operation apply lamp dielectric grease if replacing Air filter Weekly Inspect replace as needed main element Recoil housing Weekly Drain water as needed check often if operating in wet conditions 61 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Brake pad wear Monthly 100 160 Inspect periodically Battery Monthly 200 320 Check terminals clean test Front gearcase oil 25H Monthly 250 400 Inspect level change yearly if applicable gt Transmission oil Monthly 250 400 Inspect level change yearly Engine breather 25H Monthly 250 400 Inspect clean if needed filter if equipped 3M 500 800 Lubricate all fittings pivots cables etc General lubrication Carburetor float bowl Throttle Cable ETC Switch 50H 500 800 Drain bowl periodically and prior to storage Choke cable 500 800 Inspect adjust lubricate replace if necessary Carburetor air intake ducts flange Drive belt 500 800 Inspect adjust lubricate replace if necessary 500 800 Inspect ducts for proper sealing air leaks 500 800 Inspect adjust replace as needed 1000 1600 Inspect coolant strength seasonally pressure test system yearly Engine oil change 100 H 1000 1600 Perform a break in oil change at one month Oil filter change 100 H 1000 1600 Replace with oil change Oil tank vent hose 100 H 12M
52. ion of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating a Quadricycle could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating a Quadricycle 4 amp WARNING POTENTIAL HAZARD Operating the Quadricycle at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the Quadricycle which can result in an accident HOW TO AVOID THE HAZARD Always operate the Quadricycle at a speed that s proper for the terrain visibility and operating conditions and your experience 14 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid cem exhibition driving 4 WARNING POTENTIAL HAZARD Failure to inspect the Quadricycle before operating Failure to properly maintain the Quadricycle WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your Quadricycle before each use to make sure it s in safe operating condition Always follo
53. ively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the Quadricycle on such terrain Always use extra caution on rough slippery or loose terrain 4 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 17 SAFETY Operator Safety 4 WARNING 18 POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the Quadricycle or for your abilities Never operate the Quadricycle on hills steeper than 25 Practice on smaller hills before attempting large hills WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper ve SS procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the Quadricycle on hills steeper than 25 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle sudde
54. justments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 1 4 3 6 mm toe out 1 Position the vehicle on a level surface Set the handlebars in a straight ahead position and secure them in this position 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 Measure the distance between the marks and record the measurement A Move the vehicle until the chalk marks are at the rear of the tires even with the hub axle centerline Measure the distance between the marks and record the measurement B Subtract measurement B from measurement A The difference is the vehicle toe out alignment NOTE f you discover improper alignment see your Polaris dealer for service 73 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar These brakes are self adjusting 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 such as in hilly country or in muddy terrain 4 WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic me
55. ll the battery cover Secure the battery hold down strap e Verify that cables are properly routed NOTE Cables should be safely tucked away at the front and rear of the battery 97 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 NOTE Power plug leads may need to be bent down so that the battery cover can be installed NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 111 for the part numbers of Polaris products 98 MAINTENANCE Battery Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery fluid level often Maintain the fluid level between the upper and lower level marks 1 Add only distilled water Tap water contains minerals that are harmful to a battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte du
56. ly The use of low range is highly recommended for cooler PVT operating temperatures and longer component life 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 Use the throttle quickly and effectively Use low range only Use low range only Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Shift the transmission to neutral Using the throttle vary the engine RPM from idle to full throttle Repeat several times as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected 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 for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Always
57. mmendations 64 65 M Main Switch 31 Making Turns 48 121 INDEX N Noise Emission Control System 59 Oil Change 67 69 Oil Filter Change 69 Oil Pump Priming 69 Oil Recommendations 66 Oil Engine 66 69 Oil Transmission 70 71 Operator 5 6 25 Override Switch 31 Parking Brake 36 Parking on an Incline 58 Periodic Maintenance Chart 60 63 Polaris Products 111 Pre Ride Inspection 42 PVT Break in 41 PVT Drying 93 PVT System 92 93 R Radiator Coolant Level 85 Rear Drive Chain Slack 82 83 Rear 76 Recoil Housing 90 Recoil Starter 40 122 S Safe Riding 30 Safety Decals and Locations 27 29 Safety Training T Sidehilling 50 Spark 94 Spark 89 90 Specifications 108 110 Starting the Engine 43 44 Steering Assembly 76 Stop 31 Storage Tips 105 107 T Taillight Brakelight Lamp Replacement 87 Throttle Cable Freeplay 76 Throttle 33 Ti
58. n accident Never operate on hills too steep for the Quadricycle or for your abili ties Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills Check the ter rain carefully before ascend a hill Never climb hills with excessive ly slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the Quadricycle Never attempt to turn the Quadricycle around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid cross ing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to ei
59. n possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the vehicle could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The Quadricycle could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the Quadricycle through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the Quadricycle through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 55 travel slowly balance your weight carefully avoid sudden movements and 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
60. ng 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 terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 4 WARNING 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 95 MAINTENANCE Battery 4 WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Disconnect the hold down strap holding the battery in position and remove battery cover On conventional batteries remove the battery vent tube Disconnect the black negativ
61. nly while traveling uphill The vehicle could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is es required when braking while M REN traveling downhill See page 53 Always check the terrain carefully before descending a hill Shift your weight backward 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 19 SAFETY Operator Safety 4 WARNING 20 POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the Quadricycle around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 54 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Alw
62. o headlight housing and rotate clockwise firmly NOTE The bulb must be positioned so the harness installs into the lamp at the bottom 4 Reinstall the connector to the back of the headlight High Beam Adjustment The headlight beam can be adjusted vertically 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a flat wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Loosen the pivot bolt and adjust the beam to the desired position 6 Tighten the bolt and torque to 60 in lbs 7 Nm 86 MAINTENANCE Lights Taillight Brakelight Lamp Replacement If the taillight brakelight does not work the lamp may need to be replaced 1 4 5 Remove the taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly Remove the lamp 1 Apply dielectric grease to the socket and install the new lamp Test the taillight brakelight for proper operation Reinstall the gasket and lens cover Indicator Lamp Replacement 1 2 3 Remove the instrument panel if necessary to access the
63. oad capacity by the amount of trailer tongue weight Never tow any trailer on a grade steeper than 15 46 OPERATION Driving Safely Hauling Cargo 4 WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN HAULING CARGO CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increases the pos sibility of vehicle overturn LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain stable operat ing conditions ALL LOADS MUST BE SECURED 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 cen tered securely fasten load and operate with extra caution Al wee en the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND
64. 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 tank past the pressure cap and into the radiator Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water See page 111 for the part numbers of Polaris products NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 84 MAINTENANCE Engine Cooling System 4 amp WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap Radiator Coolant Level NOTE This procedure is required only if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry the level in the radi
65. oks dark or contaminated Coolant test strength fill Fog the Engine 1 2 3 Support the front end of the machine so the engine is level or tilted slightly rearward Remove the spark plug Pour 2 3 tablespoons 29 44 ml of engine oil into the hole NOTE Use a section of small hose and a small plastic squeeze bottle 4 5 106 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 recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil Treat the fuel system with Polaris Carbon Clean See page 105 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 60 Battery Storage See pages 98 101 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the vehicle with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a
66. ons 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 service needs during and after the warranty period We also take great pride in our complete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out Copyright 2007 Polaris Sales Inc information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication 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 2008 Scrambler 500 2X4 International Owner s Manual P N 9921620 Printed in U S A 2 TABLE OF CONTENTS Know Your Vehicle
67. ort and protection 4 Boots The best footwear is a pair of sturdy over the calf boots with low heels 5 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 30 FEATURES AND CONTROLS Electrical Switches 4 amp WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Override Switch 1 Reverse Speed Limiter This vehicle is equipped with a reverse speed limiter system To gain additional power while backing L depress the override switch 3 Main Switch 2 To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts OFF RUN OFF WIN NOTE Turn off the main switch to end all electrical power to the vehicle including the lights 4 WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use Engine Stop Switch 3 The engine will not start or run when the switch is in its OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency
68. pe harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 5 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 6 Repeat steps 4 5 if necessary CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 40 OPERATION Break In Period The break in period for your new Polaris Quadricycle is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components CAUTION 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 the fuel tank with gasoline see page 38 ADD 8 OZ NORMAL FULL 2 Check the oil level
69. proceeding 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 run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove the arrestor clean out plug 1 from the bottom of the muffler Place the transmission in neutral and start the engine Purge carbon from the system by momentarily revving the engine several times If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Lock the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug MAINTENANCE Battery Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery sealed battery can be identified by its flat covers on the top of the battery conventional battery has six filler caps on the top of the battery Conventional Battery Always keep battery terminals and connections free of corrosion If cleani
70. ps See page 111 for the part numbers of Polaris products CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 102 Fuel Stabilizer 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 NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl and Filter Change the oil and filter See page 67 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Drain the sediment tube Recoil Housing Drain the recoil housing See page 90 105 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 60 Demand drive unit front gearcase Rear gearcase if equipped Transmission Brake fluid change every two years and any time the fluid lo
71. r right until it s pointing across the hill or slightly downward Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the brake until the vehicle is on more level ground OPERATION Driving Safely Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to ds s c the bottom of the pos pe 95 footrests 1 Follow ds d 7 Pa 2 S these procedures when IZ X ue operating through water xy o AT 1 Determine water depths and current before crossing 1 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 60 The following areas need special attention engine oil transmission oil front and rear gearcases if equipped and all grease fittings 4 CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to
72. rating at a ground speed of 3 MPH the engine would be running at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engagement point the engine may be running at a speed too low to provide the adequate pinch needed to prevent incomplete engagement Incomplete engagement creates excessive heat that can destroy belts and clutch covers In some cases excessive clutch wear and damage may result If the vehicle will be operated for extended periods below 5 MPH 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 extends the life of the PVT components belt cover etc NOTE Avoid heavy pulling and extended low speed operation 92 MAINTENANCE PVT System 4 WARNING 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 conduct
73. re Tread 81 Toe Alignment 73 Towing 46 Transmission Gear Selector 39 Transmission Oil 70 71 Transporting the Quadricycle 107 Turning Around ona Hill 54 V Vehicle Identification Numbers 5 Vehicle Immersion 91 Warranty 116 117 Washing the Vehicle 102 103 Wheel Installation 80 Wheel Nut Torque Specifications 80 Wheel Removal 79 Wheels b mas 79 81
74. ressure to brake the rear wheels without skidding 1 Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the foot brake Maintain the fluid level between the maximum and minimum marks 37 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 43 for correct choke and throttle settings during starting Fuel Valve The fuel valve 1 is located on the left side of the vehicle below the fender It has three positions OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return the valve to the ON position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Refer to the specifications section at the rear of this manual for tank capacity 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 38 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 i
75. ri cycle Never permit a guest to operate the Quadricycle unless the guest has read this manual and all product labels and has completed a certified safety training course Never operate a Quadricycle without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating a Quadri cycle Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your Quadricycle before each use to make sure it s in safe operating condition Always follow the inspection and mainte nance procedures and schedules outlined in your owner s manual Always keep both hands on the handlebars and both feet on the foot rests of the Quadricycle during operation Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds SAFETY Operator Safety Always have the Quadricycle inspected by an authorized Polaris dealer if it s been involved in a
76. ring charging See page 96 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 gravity to 1 270 or greater 3 Reinstall the battery See page 97 Make sure the positive terminal is toward the front of the vehicle 99 MAINTENANCE Battery Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage 4 WARNING An overheated battery could 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 NOTE When using an automatic charger refer
77. s With dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information 29 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding Quadricycle riding requires special protective clothing for comfort and to reduce the chance of injury 1 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 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The 051039 approval number and serial 0006 031 number will also be displayed on the label 2 Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean 3 Gloves Off road style gloves with knuckle pads are the best for comf
78. s located on the right side of the vehicle F F Forward N Neutral N R Reverse R CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Whenever the vehicle is left unattended always place the transmission in gear and lock the parking brake 39 FEATURES AND CONTROLS Recoil Starter If the battery has been drained or damaged and cannot start the engine use of the recoil starter 1 will allow vehicle operation until repairs can be made The recoil starter is located on the right side of the machine Polaris 4 cycle engines are equipped with automatic decompressors This makes recoil starting possible by reducing the amount of compression during starting The decompressor senses when the engine is spinning fast enough to start and restores compression when running 1 Position the vehicle on a level surface and lock the parking brake see page 36 2 Shift the transmission into neutral 3 Make sure the engine stop switch is set to RUN and the main key switch is in the ON position NOTE Ifthe engine is cold use the choke as outlined on page 43 4 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke will be a compression stroke and will make the ro
79. s 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 LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 28 Safety Decals and Locations No Passenger Warning 4 WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH Age 16 Warning 5 WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 Tire Pressure Load Warning 6 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY 305 LBS 138 kg INCLUDES WEIGHT OF OPERATOR CARGO AND ACCESSORIES Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured to the rack
80. safe operating procedures Review this information on a regular basis If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer please request free safety training from any authorized Polaris dealer Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Equipment Modifications The warranty on your Polaris Quadricycle 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 NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Operator Safety 4 WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully and follow the operating procedures described Never operate a Quadricycle without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www polarisindustries com Never allow anyone under 16 years of age to operate this Quad
81. se the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled 6 Ifthe engine is cold pull the choke knob out until it stops 1 NOTE The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components NOTE If the knob doesn t stay where positioned increase the tension by rotating the tension adjusting nut 2 clockwise 43 OPERATION Starting the Engine 7 Move the engine stop switch to RUN NOTE not press the throttle while starting the engine 8 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts If the engine does not start release the key and wait five seconds Activate the starter for another five seconds Repeat this procedure until the engine starts NOTE If a warm engine has cooled to a point where it does not 10 44 readily start intermittent use of the choke button 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 th
82. spect condition and pressure 34 74 MIN om css d REN 33 76 31 32 Wheels fasteners nspect ensure fastener tightness nspect ensure tightness Ensure proper levels Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Indicator lights switches Engine stop switch Drive chain Frame nuts bolts fasteners Fuel and oil Ensure proper operation Ensure operation 33 76 31 32 Ensure proper operation Check condition slack lubricate as 72 82 needed Air filter pre filter Inspect clean Air box sediment tube Headlamp Drain deposits whenever visible Check operation apply Polaris dielec tric grease when lamp is replaced Check operation apply Polaris dielec tric grease when lamp is replaced Wear helmet goggles protective clothing Brake light tail lamp 4 o Riding gear 42 OPERATION Starting the Engine 4 amp WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Lock the parking brake NOTE The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged 4 Turn the fuel valve on 5 Sit on the vehicle NOTE Do not u
83. t Tait Brake Ligh Baten DC Plugin Read DC Socket Forward Plecire Sta High Beam indicato High Temp Indicator Windshield Low OW Lig Neutral indica Speedometer Fuel Gauge Toot Kit 109 SPECIFICATIONS 2008 Scrambler 500 2X4 International Jetting Chart Altitude AMBIENT Below 40 F 40 F and above TEMPERATURE Below 5 C 5 C and above Meters 0 1800 Feet 0 6000 1800 3700 6000 12000 Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Spring Weight Spring Spring Setting Meters 0 1800 10WH Blue Green Silver 40 Feet 0 6000 5630710 7041157 7041499 5131446 1 1 1800 amp above 10RH Blue Green Silver 40 6000 amp above 5630709 7041157 7041499 5131446 1 1 110 POLARIS PRODUCTS Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube qt 2873603 Premium AGL Synthetic Gearcase Lube gal 2871653 Premium ATV Angle Drive Fluid 8 oz 2872276 Premium ATV Angle Drive Fluid 2 5 gal 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 287
84. t a pin punch 2 through the sprocket hub and into the eccentric housing 82 MAINTENANCE Rear Drive Chain Slack 6 Roll the vehicle forward or backward to adjust the chain slack to the proper tension See the illustration for proper splice link clip opening position 1 1 7 Tighten the eccentric locking bolts A to 30 ft Ibs 41 Nm for machines CA 1 without the hitch and 45 ft Ibs 61 Nm for machines with a hitch 8 Tighten the caliper mount bolt to 15 ft Ibs 20 Nm 9 Remove the pin punch 10 Roll the vehicle forward checking chain tension in several places around the chain NOTE The chain is adjusted correctly when the tightest portion of the chain has approximately 3 8 10mm deflection 11 Position the chain guide to allow 1 8 3mm clearance and tighten the retaining bolt to 5 ft Ibs 7 Nm 12 Reinstall the chain guard 83 MAINTENANCE Engine Cooling System Coolant Level The recovery bottle 1 is located on the left side of the machine The fluid level must be maintained between the minimum and maximum marks on the bottle when the fluid is cool The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out
85. tained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer Electromagnetic Interference This spark ignition system complies with USA requirements Canadian ICES 002 and European directives 89 336 EEC and 97 24 EC 59 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 118 NOTE 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 Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed
86. ther side if the Quadricycle is pointed straight uphill Turn the Quadricycle around and remount following the pro cedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Avoid operating the Quadricycle through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes SAFETY Operator Safety e Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads e Always check for obstacles or people behind the vehicle before oper ating in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your vehicle and always maintain proper tire pressure Never modify a Quadricycle through improper installation or use of accessories Never exceed the stated load capacity for your vehicle Cargo m
87. to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging 100 MAINTENANCE Battery Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Voltage Charge Time Charge Using constant current charger 2 standard amps specified on top of battery 10096 12 8 13 0 volts None check at None required 3 mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 50 75 12 0 12 5 volts Needs Charge 5 11 hours 50 11 5 12 0 volts Needs Charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs Charge At least 20 hours 25 101 MAINTENANCE Cleaning and Storage See page 111 for the part numbers of Polaris products Washing the Vehicle Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components CAUTION High water pressure may damage vehicle components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellants and chemicals will damage plastic surfaces Do not allow these types of products to come into contact with the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and wat
88. usceptible to accident or injury HOW TO AVOID THE HAZARD Never allow anyone under 16 years of age to operate this vehicle 11 SAFETY Operator Safety 4 WARNING 12 POTENTIAL HAZARD Carrying a passenger on a Quadricycle WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the Quadricycle which could cause an ee accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this Quadricycle without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating a Quadricycle without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants 13 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the Quadricycle after consuming alcohol or drugs WHAT CAN HAPPEN Consumpt
89. use the recommended belt Improper break in Always break in a new belt and or clutch by avoiding aggressive or high speed operation during the first two full tanks of fuel TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12 8 VDC Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 113 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 114 Kinked or plugged fuel vent line Inspect and replace TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugge
90. ust be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT QUADRICYCLE SAFETY contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www polarisindustries com 10 SAFETY Operator Safety amp WARNING POTENTIAL HAZARD Operating this Quadricycle without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the Quadricycle properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Never operate a Quadricycle without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www polarisindustries com 4 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this Quadricycle WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates a Quadricycle Even though a child may be within the recommended age group for operating some Quadricycles he she may not have the skills abilities or judgment needed to operate a Quadricycle safely and could be s
91. w the inspection and maintenance procedures and schedules described in the owner s manual 15 SAFETY Operator Safety 4 WARNING 16 POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the Quadricycle If the operator s foot is not firmly planted on the footrest it could come into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the Quadricycle during operation WARNING POTENTIAL HAZARD Failure to use extra caution when operating the Quadricycle on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excess

Polaris 9921123 Offroad Vehicle User Manual

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