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John Deere 5083EN Lawn Mower User Manual

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1. VEHICLE SERIES TRADE NAME MODEL SOUND YEARS PRESSURE dB A __KA05__ OUTLAW 50 2008 2009 2010 76 8 _KA09__ OUTLAW 90 2008 2009 2010 76 8 FAO SPORTSMAN 90 2008 2009 2010 76 8 O VAI RZR 170 2009 2010 81 3 __PB20 __ PHOENIX 200 2008 2009 2010 76 8 _BA32__ TRAIL BLAZER 330 2008 2009 2010 76 8 _CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 BA50 SCRAMBLER 500 2008 2009 2010 79 6 G OUTLAW 450 2008 2009 2010 80 7 GJ52_ GP52 OUTLAW 525 2008 2009 2010 80 7 I7 SPORTSMAN 300 2008 2009 2010 81 1 LH SPORTSMAN 400 2008 2009 2010 80 2 MN50 SPORTSMAN 500 EFI 2008 2009 2010 80 4 ZN55 ZX55 SPORTSMAN 550 EFI 2009 2010 80 8 TN55 DN55 SPORTSMAN X2 TOURING 550 2010 77 2 ___MN76_ SPORTSMAN 800 2008 2009 2010 83 6 TN85 _ DN85 SPORTSMAN X2 TOURING 850 2010 77 2 __ CL76 SPORTSMAN 800 6X6 2009 2010 80 1 ZN85_ __ZX85 SPORTSMAN 850 EFI 2009 2010 80 4 RH50 HH50 RANGER 500 EFI 4X4 2009 2010 76 5 HA6 RANGER 800 EFI 4X4 2010 76 5 WH76 RANGER 800 EFI CREW 2010 76 5 AR RANGER 800 6X6 2010 76 5 HY _ RANGER HD 800 4X4 2010 76 5 ___VH76__ RANGER RZR 2008 2009 2010 85 8 Authorized Signatory Abe tater hy h Pamata Alexander A Kennedy Product Compliance Polaris Industries Inc Engineering Operations 301 5th Avenue SW Roseau MN 56751 106 WARRANTY LIMITED WARRANTY
2. Overall Length 75 in 190 5 cm Overall Width 45 in 114 cm Overall Height 49 in 124 5 cm Wheelbase 48 5 in 123 cm Ground Clearance 4 75 in 12 cm Minimum Turning Radius 65 in 165 cm unloaded Engine Model Number Type EHSOPLE 129 4 Cycle Single Cylinder Lubrication Dry sump Engine Cooling Liquid Displacement 498 cc Bore x Stroke 92 x 75 Alternator Output 250w 5000 rpm Compression Ratio 10 2 1 Carburetor BST 40 Pilot Jet 37 5 Main Jet 155 Needle Jet X 6M Jet Needle 6MGHI 194 4 Pilot Air Jet 1 3 Pilot Screw 3 turns Ignition System CDI Ignition Timing 30 2 5000 RPM Idle RPM 1350 Spark Plug Gap BKR6E 036 in 9 mm Based on EU Directive 76 432 EC 104 SPECIFICATIONS Scrambler 500 4X4 International Driving System Type Automatic PVT Polaris Variable Transmission Shift Type Side Lever F N R Gear Reduction Reverse 4 74 1 Gear Reduction Forward 3 06 1 Drive Ratio Front 3 818 1 Drive Ratio Final 2 77 1 Drive Chain 520 O Ring Tires Pressure Front 23 x 7 10 4 psi 27 6 kPa Tires Pressure Rear 22 x 11 10 G psi 20 7 kPa Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 10 5 26 7 cm travel Shock Adjustment CAM Hand Brake Single Control Hydrau
3. Loosen the carburetor drain screw and drain the carburetor Turn the engine over several times using the electric start Dry the spark plug Reinstall the plug or install a new plug Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If neces sary repeat the drying procedure Drain Screw Have the vehicle serviced by your dealer promptly whether you succeed in starting it or not If water has been ingested into the transmission follow the proce dure on page 85 for drying 81 MAINTENANCE Spark Arrestor AWARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Never run the engine in an enclosed area Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never go under the vehicle while it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Position the vehicle on a level surface 2 Place the transmission in Exhaust neutral Outlet Ty 3 Lock the parking brake i AN 4 Remove the arrestor clean Clean Out Plug out plug from the bottom of the muffler 5 Start the
4. Use the main key switch to start the engine See page 31 for starting pro cedures All Wheel Drive Switch See page 28 for all wheel drive information Main Key Switch All Wheel Drive Switch 21 FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers Always check and adjust the mirrors before driving the vehicle Indicator Lights With the engine running verify the function of all indicator lights before each use of the vehicle Tip The taillight is on whenever the main switch key is on Turn the key off to prevent battery drain Reverse Turn Signal Hazard Indicators Indicator High Beam Indicator Neutral Indicator High Temperature Warning displays if engine overheats 22 FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement Release the ha E lever to reduce engine speed and vehicle movement PRS gt a A Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Check the lever for proper operation before starting the engine Check occasionally during operation Do not start or operate a vehicle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Electronic Throttle Control ETC ETC causes the engine to stop if the throttle cable Electro
5. Treat the fuel system with Polaris Carbon Clean See page 95 Support the front end of the machine so the engine is level or tilted slightly rearward Remove the spark plug Pour 2 3 tablespoons 30 40 ml of engine oil into the hole Use a section of small hose and a small plastic squeeze bottle filled with the pre measured amount of oil Reinstall the spark plug Torque to specification Apply dielectric grease to the inside of the spark plug cap Reinstall the cap Turn the engine over several times using the electric start Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil If Polaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 47 Battery Storage See pages 89 90 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 genuine Polaris cover Do not use plastic or coated mate rials They do not allow enough ventilation to prevent condensat
6. Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission Premium AGL Synthetic 32 oz 14 ft Ibs 14 ft Ibs Gearcase Lubricant 946 ml 19 Nm 19 Nm Oil Check 1 Position the vehicle on a level sur face 2 Remove the propshaft shield from the right side of the vehicle to access the fill plug Remove the fill plug 3 Check the oil level Add oil as needed Do not overfill 4 Reinstall the fill plug Torque to l specification Fill Plug S 56 MAINTENANCE Transmission Oil Oil Change l 2 BO Sy U Position the vehicle on a level surface Remove the propshaft shield from the right side of the vehicle to access the fill plug Remove the fill plug Remove the transmission drain plug located on the bottom left hand side and drain the oil into an appropriate container Discard used oil properly Clean and reinstall the drain plug Torque to specification Add the proper amount of the recommended lubricant Reinstall the fill plug Torque to specification Check for leaks Reinstall the propshaft shield 57 MAINTENANCE Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the intervals out lined in the Periodic Maintenance Chart beginning on page 47 Maintain the fluid level at the bottom of the fill hole threads See page 99 for the part numbers of Polaris products Fluid Recommendations Gearcase Lubricant C
7. MAINTENANCE Carburetor Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C or higher Above 1800 meters the engine air fuel mixture becomes too rich and the engine loses approximately 3 of its power for each 300 meter increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets and clutch components available from your Polaris dealer are required for operation above 1800 meters and at temperatures below 4 degrees C Tip Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting the vehicle for condi tions in your area Carburetor Engine Idle RPM Adjustment If the engine idle speed is not satisfac tory and all other conditions are favor poe able the carburetor can be adjusted S 1 Place the transmission in gear Lock the parking brake 2 Start the engine and allow it to warm up for approximately five minutes 3 Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM Adjuster 70 MAINTENANCE Drive Chain Drive Chain Lubrication The drive chains are equipped with o ring sealed permanently greased pins and rollers However t
8. Pantone 425C Scrambler 4X4 Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age 7 antone AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVERCARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 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 9922463 Rev 01 Printed in U S A 100 RECYCLED The text is printed on 100 recycled with 40 post consumer waste PCW 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 r
9. Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris vehicle against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehcile is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 107 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does no
10. 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 VIN Key Number Vehicle Model Number Frame VIN Engine Serial Number right front side of engine crankcase Key Number SAFETY Failure to operate the vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Equipment Modifications We strongly recommend that consumers do not install on a Polaris vehi cle any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your Polaris vehicle is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Safe Riding Gear Always wear appr
11. the maintenance chart See page 47 The following areas need special attention engine oil transmission oil front and rear gearcases if equipped and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 81 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than the footrest level e Proceed slowly Avoid rocks and obstacles e Balance your weight carefully Avoid sudden movements e Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 40 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles l 2 Always check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible Never attempt to operate over large obstacles such as rocks
12. Lamp Replacement 1 2 78 Remove the instrument panel if necessary to access the back of the indicator panel Using a small straight blade screwdriver turn the base of the bulb 1 4 turn counterclockwise Using a needle nose pliers or similar tool pull the lamp out of the indicator panel housing Insert the new bulb and seat it by turning it 1 4 turn clockwise Reinstall the instrument panel if removed MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 104 for the recom mended spark plug type and gap for your vehicle NOTICE Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Plug Condition Torque Specification New Spark Plug 12 15 Nm Previously Installed Spark Plug 23 27 Nm Spark Plug Inspection Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immedi ately check the spark plug for correct color See page 80 A A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Inspect the electrodes for wear and carbon buildup Replace aw worn or fouled plugs Verify that the gap is at specification be
13. a constant current charger use the following guidelines for recharging 90 Battery MAINTENANCE Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 91 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body
14. all forward speed is lost Keep your weight uphill If the vehicle begins rolling downhill never apply engine power Never apply the brakes aggressively while rolling backwards Apply the brakes gradually When fully stopped lock the parking brake See page 25 Dismount on the uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around using the K Turn See page 39 36 OPERATION Driving on a Sidehill Sidehilling Avoid crossing the side of a hill sidehilling if possible If sidehilling is necessary follow these precautions Slow down Avoid hills with excessively slippery or loose surfaces Avoid crossing the sides of steep hills Shift your weight uphill Keep your feet on the footrests If the vehicle begins to tip quickly turn the front wheels downhill if possible or dismount on the uphill side immediately ON eR i BO 37 OPERATION Driving Downhill 25 Maximum When driving downhill follow these precautions l mo eor oy 38 Check the terrain carefully Avoid hills with excessively slippery or loose surfaces Never drive downhill at high speed Slow down Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side Drive straight downhill Shift your weight rearward Apply the brakes slightly to aid in slowing OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hil
15. contracting cooled coolant is drawn back up from the bottle past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 99 for the part num bers of Polaris products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle 1 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 2 Add coolant as needed Recovery Bottle 74 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed A Escaping steam can cause burns Never remove the pre
16. cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 12 If the engine slows or stops position the choke knob half way in to 32 allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in OPERATION Driving Procedures N SU ee Da Wear a helmet and eye protection See page 8 Sit upright Keep your feet on the footrests Keep both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly squeeze the throttle lever toward the handlebar to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 33 OPERATION Turning the Vehicle l 34 Before turning activate a turn signal to alert oth ers of your intentions Activate the left signal before a left turn Acti vate the right signal before a right turn Steer in the direction of the turn leaning your upper body to the inside of the turn while sup porting your weight on the outer footrest Use the same leaning tech nique for turning in reverse Practice turning at slow speeds before attempting to turn at faster speeds OPERA
17. engine 6 Quickly squeeze and release the throttle lever several times to purge carbon from the system 7 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 8 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 6 9 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 10 Repeat steps 6 to 8 until no more particles are expelled 11 Stop the engine Allow the arrestor to cool 12 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 82 MAINTENANCE PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e This PVT system
18. inside the clutch cover greatly extends the life of the PVT components belt cover etc Tip Avoid heavy pulling and extended low speed operation 84 MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing l 2 3 Move the vehicle out of the water Remove the PVT drain plug Allow the water to drain completely Reinstall the drain plug Start the engine Place the transmission in neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed then shift the trans mission into forward gear Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 85 MAINTENANCE Battery AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities o
19. low range if equipped Care fully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 85 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph 48 km h for one mile 1 6 km Operate 5 miles 8 km or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 29 100 Engine Doesn t Turn Over Possible Cause Tripped circuit breaker TROUBLESHOOTING Solution Reset the breaker Low battery voltage Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Turn fuel valve to reserve refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turne
20. on the hose that runs between the engine and air box 1 Remove the clamps and pull the breather filter out of the hoses It s not necessary to remove the lower hose from the engine 2 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if needed 3 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 4 Reinstall the filter and secure the clamps The filter is effective with the arrow pointing in either direction A Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for service 68 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference A 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 Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the handlebar cover to Handlebar Bolts access the handlebar bolts Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height 4 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 5 Torque the front two bolts to 14 17 Nm then torque the rear two bolts A gap of up to 3 mm will remain at the rear bolts 69
21. operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 26 2 Check the oil level Add oil if necessary 3 Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Drive slowly Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 30 6 Pull only light loads 7 Change both the oil and the filter at 20 hours or one month PVT Break in Clutches Belt Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggres sive acceleration and high speed operation during the break in period 29 OPERATION Pre Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condi tion before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition protective clothing Item Remarks Page Hand brake Ensure proper operation 24 Brake fluid Ensure proper level 59 Foot brake Ensure proper operation 24 Front suspension Inspect lubricate if necessary 51 Rear suspension Inspect lubricate if necessa
22. 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 0z 185 ml 2872348 Chain Lube Aerosol 16 0z 473 ml Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger 99 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Starting out going up a steep incline Solution Use low range if equipped or turn around using the K turn see page 39 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range if equipped more frequently Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only if equipped Utility use plowing Use low range only if equipped Stuck in mud or snow Climbing over large objects from a stopped position Shift the transmission to
23. CE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 92 Stabilize the Fuel 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 53 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Clean or replace the breather filter 4 Drain the sediment tube 95 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 47 e Demand drive unit front gearcase Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill Fog the Engine l 96
24. Polishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 93 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 94 MAINTENAN
25. Prime the oil pump using the procedure on page 55 Then stop the engine and inspect for leaks 16 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 17 Discard used oil and filter properly 54 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has 2 5 cm Relief been disconnected Slit 1 Clamp or pinch off the vent line approximately two inches 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Run the engine for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation Jf you do not hear air the line has not bled and you ll need to repeat the priming procedure 55 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 Maintain the oil level at the bottom of the fill hole threads See page 99 for the part numbers of Polaris products The fill plug is located on the left side of the vehicle under the rear fender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations
26. ROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough ter rain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 16 SAFETY Safety Labels and Locations General Warning Discretionary Warning Discretionary Warning WARNING e Never operate this ATV on HILLS steeper than 25 degrees 25 To pre vent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns 7175511 17 SAFETY Safety Labels and Locations Tire Pressure Load Warning i Age 16 Warning La No Passenger Warning Clutch Cover Warning No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7175378 Tire Pressure Load Warning WARNING Improp
27. Renta he ead sey aie ace 9 Brake Fluid 59 60 Brake Inspections 61 Brake Foot 000000e 24 Brake Hand 3 3 c4ccuss dee deta 24 Brake Parking 25 Brakes s is 635 2 ad cae 24 25 61 Break In Period 29 Breather Filter 68 Cc Carburetors lt is hea aaatee ya saks 70 Carburetor Adjustment 70 Care0s ey kaye eae os 44 45 Choke sone vanes Gad eoadediess 26 Chrome Wheel Care 94 Cleaning and Storage 92 97 Clothing ereen i tle ees 9 Clutching Chart 105 Coolant Bottle 74 Coolant Radiator 75 Cooling System 74 75 Corrosion Removal Chrome 94 D Demand Drive Fluid 58 Drive Belt Wear Burn 100 Drive Chain 71 73 Drive Chain Lubrication 71 Drive Chain Slack 72 73 Drivetrain Break In 29 Driving Downhill 38 Driving in Reverse 42 Driving on a Sidehill 37 Driving on Slippery Surfaces 35 Driving Over Obstacles 4 Driving Procedures 33 Driving Through Water 40 Driving Uphill 36 E Electromagnetic Interference 46 Engine Break In 29 Engine Fogging 96 Engine Idle RPM Adjustment 70 Engine Oil ossa 2203s eee4e eens 52 Engine Sto
28. TION Driving on Slippery Surfaces Sideways Turn in skid y direction of skid Sa eaa NN d OT 1 lt gt lt gt fal C C Co cC y S Cec VW Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage AWD before wheels begin to lose traction NOTICE Severe damage to drive train may occur if AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction 4 Bealert 5 Watch the trail 6 Avoid quick sharp turns Tip To correct a rear wheel skid turn the handlebars in the same direction as the skid and shift body weight forward 35 OPERATION Driving Uphill Whenever traveling uphill follow these pre cautions 1 Avoid steep hills 25 maximum 2 Check the terrain carefully 3 Avoid hills with excessively slippery or loose surfaces 4 Shift your weight uphill 5 Drive straight uphill 25 Maximum Keep your feet on the footrests 7 Drive at a steady rate of speed to avoid stalling 8 Be alert Be prepared to take emergency action This may include dismounting quickly 9 Never open the throttle suddenly or make sudden gear changes 10 Never go over the top of a hill at high speed If
29. TY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn NEVER CARRY CARGO ON THE FRONT OF THE VEHICLE DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level surface Vehicl
30. aco Pa ee waite tenn thas 92 97 Suspension Adjustments Rear 63 Switches 0 0 ee eee 20 21 All Wheel Drive Switch 21 Engine Stop Switch 20 Hazard Switch 21 Headlight Switch 21 Horn Switch 21 Main Key Switch 21 Override Switch 20 Turn Signal Switch 21 T Throttle Cable Freeplay 64 Throttle Lever 23 Tire Tread Depth 65 PUN OS 0 9 5 59 46 9 5 5 0 5 56 80 n stan Se 65 67 Front Wheel Hub Tightening 65 Tread Depth 65 Wheel Installation 66 Wheel Nut Torque 67 Wheel Removal 66 Toe Alignment 62 Towing Loads 45 Training Safety 5 Transmission Oil 56 57 Transporting the Vehicle 98 Turn Signal Switch 21 Turning Around ona Hill 39 Turning the Vehicle 34 V Vehicle Identification Numbers 6 Vehicle Immersion 81 Ww Warning Symbols 4 Washing the Vehicle 92 93 Wheel Hub Tightening 65 Wheel Installation 66 Wheel Nut Torque Specifications 67 Wheel Removal 66 115
31. aler for ser vice A Operating the vehicle with a spongy brake can result in loss of braking which could cause an accident Never operate the vehicle with spongy feeling brakes If the fluid level is low add DOT 4 brake fluid only See page 99 for the part numbers of Polaris products A 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 Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A 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 59 MAINTENANCE Brake Fluid Hand Brake The master cylinder is Master Indicator located on the left Cylinder Window handlebar Maintain the fluid level 6 mm below the top edge of the master cylinder Do not overfill 1 Position the vehicle on a level surface Make sure t
32. ank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Fuel Valve The fuel valve is located on the left side of the vehicle below the fender Cap ON For normal operation OFF For vehicle storage and when transporting Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 26 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle Tip Place the steering lock keys in a safe place The lock must be replaced if the keys are lost 1 Turn the handlebars to the full left posi tion 2 Insert the steering lock key and turn it clockwise Remove the key 3 Reverse the procedure to unlock the steering A The handlebars are locked in the full left position when the steering is locked Always unlock the steering before starting the engine 27 FEATURES AND CONTROLS All Wheel Drive AWD System The AWD switch may be turned on or off while the vehicle is moving AWD will not engage until engine speed is below 3100 RPM AWD remains engaged until the switch is turned off There is no limit to the length of time the vehicle may remain in AWD If the switch is turned o
33. apacity Fill Plug Drain Plug Torque Torque Front Demand Drive LT 9 oz 8 10 ft Ibs 11 ft Ibs Gearcase Premium Fluid 265 ml 11 14 Nm 15 Nm Fluid Check The fill plug is located on the right side of the demand drive unit 1 Position the vehicle on a Fill level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads l 4 Reinstall the fill plug FIL avel Drain Plug Torque to specification Fluid Change The drain plug is located on the bottom right side of the unit 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to specification Add the recommended fluid to capacity Reinstall the fill plug Torque to specification Check for leaks Dispose of used fluid properly BOSON A 58 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride Always maintain brake fluid at the recommended level Do not overfill The brakes should feel firm when they re applied Spongy or weak brakes may indicate a fluid leak or low fluid level A low fluid level may also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongy or weak brakes See your de
34. bles etc Carburetor float 50H 6M 500 800 Drain bowl periodically and bowl prior to storage E Throttle Cable 50H 6M 500 800 Inspect adjust lubricate E ETC Switch replace if necessary E Choke cable 50H 6M 500 800 Inspect adjust lubricate E replace if necessary E Carburetor air 50H 6M 500 800 Inspect duct for proper seal intake ducts flange ing air leaks Drive belt 50H 6M 500 800 Inspect adjust replace as needed Cooling system 50H 6M 1000 1600 Inspect coolant strength if applicable seasonally pressure test system yearly gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at 20 hours gt Oil filter change 100 H 6M 1000 1600 Replace with oil change gt Oil tank vent hose 100 H 12M 1000 1600 Inspect routing condition if equipped Valve clearance 100 H 12M 1000 1600 Inspect adjust E Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 49 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Radiator 100 H 12M 1000 1600 Inspect c
35. cle is not a toy and can be hazardous to operate A collision or rollover can occur quickly even during routine maneuvers if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating this Polaris vehicle Safety Training When you purchased your new Polaris vehicle your dealer offered a hands on safety training course You were also provided with printed materials that explain safe operating procedures Review this informa tion on a regular basis If you purchased a used Polaris vehicle 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 Restrictions This vehicle is approved for OFF ROAD TOWING ONLY Towing a trailer with this vehicle on public roads is prohibited Equipment Modifications The warranty on your Polaris vehicle may be terminated if any equip ment has been added or if any modifications have been made that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers and large racks may change vehicle handling Use only Polaris approved accessories Know their function and effect on the vehicle INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided
36. d off Turn the fuel valve on Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is up Overuse of choke Clogged fuel filter Inspect clean and or replace spark plugs Replace the filter Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Exhaust leaks Replace exhaust seals 101 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Solution Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Engine Runs Irregularly Stalls or Misfires Possible Cause Fouled or defective spark plugs Soluti
37. d the rotation arrows on the tire pointing toward forward rotation 2 Install the wheel nuts finger tight On vehicles with tapered rear wheel nuts make sure the tapered ends of the nuts fit into the tapers on the wheels 3 Lower the vehicle to the ground Torque the wheel nuts to ONG specification page 67 A Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification 66 MAINTENANCE Tires Wheel Nut Torque Specifications 27 ft Ibs 7 Nm 50 ft Ibs 68 Nm Check the wheel nut torques occasionally and when they ve been loos ened for service Item Torque Specification Front Wheel Nuts 27 ft Ibs 37 Nm Rear Wheel Nuts 50 ft Ibs 68 Nm 67 MAINTENANCE Air Filter 1 Remove the seat Pre Filter 2 Release the air box cover Main Filt clips and remove the air aE neE box cover 3 Loosen the clamp and remove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main filter if needed 6 Reinstall the filter into the Breather air box and tighten the Filter clamp Do not over tighten the clamp as filter damage could occur 7 Reinstall the air box cover and the seat Breather Filter The breather filter is
38. de the best protection SAFETY Operator Safety A Read and understand all warnings cautions and operating procedures in this manual and on the safety labels before operating the vehicle Never operate this vehicle without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris dealer or visit the Polaris web site at www polarisindustries com Never permit others to operate the vehicle unless they have read and under stand this manual and all product labels and have completed a certified safety training course A Never allow anyone under 16 years of age to operate this vehicle Never carry a passenger 10 SAFETY Operator Safety A Always wear an approved helmet that fits properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants A Never consume alcohol or drugs before or while operating this vehicle A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience A Never attempt jumps or other stunts 11 SAFETY Operator Safety A Always inspect your Polaris vehicle before each use to verify that it s in safe operating condition Follow the inspection and maintenance procedures outlined in this manual See page 30 A Keep both hands on the handlebars Keep your feet on the footrest
39. e Be careful not to tip a conven tional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 20200 SIRO Ps ee Na 87 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 90 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte A 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 On conventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Install the battery cover if equipped Secure the battery hold down strap Verify that cables are properly routed Cables
40. e speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 44 OPERATION Hauling Cargo Load Distribution Accessory racks and hitches are available from your Polaris dealer Read and understand the load distribution warnings listed on the vehicle warning labels Never exceed the specified weights Never carry cargo on the front of the vehicle Cargo should be evenly distributed and mounted as low as possible on the rear rack When operating over rough or hilly terrain reduce speed and cargo or towed load to maintain stable driving conditions Towing Loads Towing is approved OFF ROAD ONLY Do not exceed the maximum capacities when towing Do not tow any trailer on a grade steeper than 15 Always attach a towed load to the hitch point Remove the hitch when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle 45 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 Spark Arrestor Your Polaris vehicle has a spark arrestor that was des
41. eadjust cable freeplay if this occurs 64 MAINTENANCE Tires AWARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident e Maintain proper tire pressure as described on the label on your vehicle and in the specifications section of the owner s manual e Use only original equipment size and type when replacing tires e Make sure the wheels are installed properly e Replace tires when the tread depth measures 3 mm or less Refer to the specifications section beginning on page 104 for recom mended tire type size and pressure Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer Tire Tread Depth Always replace tires 3mm when tread depth is worn to 3 mm or less PS 65 MAINTENANCE Tires Wheel Removal 1 Position the vehicle on a level surface Place the transmission in gear Lock the parking brake 2 Loosen the wheel nuts slightly A Do not service axle nuts that have a cotter pin installed See your Polaris dealer 3 Place a suitable stand under the footrest frame to raise the wheel slightly off the ground 4 Remove the wheel nuts 5 Remove the wheel Wheel Installation 1 Place the wheel on the wheel hub with the valve stem toward the outside an
42. ecreational products e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory Motorcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Please see your dealer for all of your service needs during and after the warranty period For more information about Polaris visit us online at www polarisindustries com CY POLARIS The Way Out POLARIS THE WAY OUT and SCRAMBLER are registered trademarks of Polaris Industries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2010 Scrambler 4X4 International Owner s Manual P N 9922463 2 TABLE OF CONTENTS Introduction o
43. er tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death e Cold tire pressure Front 4 0 psi 27 6 kPa Rear 3 0 psi 20 7 kPa e Maximum weight capacity 275 Ibs 125 kg 7175443 18 SAFETY Safety Labels and Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7175374 Clutch Cover Warning WARNING e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed e Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7172563 Reverse Override Warning WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse 7175486 4X4 Caution CAUTION Do not push switch to engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage 7175485 19 FEATURES AND CONTROLS Switches Engine Stop Switch p The engine will not start i or run when the switch is NG in the OFF position Headlight D OFF Switch Engine w RUN Stop Push the stop switch Switch down to s
44. f the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 88 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage A An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using
45. f water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 86 MAINTENANCE Battery Battery Removal Place the transmission in gear Lock the parking brake Remove the seat Disconnect the battery hold down strap Remove the battery cover if equipped On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the vehicl
46. ff while the demand drive unit is engaged it will not disengage until the rear wheels regain traction Engage AWD before getting into situations where maximum traction is needed If the rear wheels are spinning release the throttle before switching to AWD Tip The override switch allows activation of AWD in reverse if the AWD switch is on A Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest AWD When the AWD switch is on the vehicle is in four wheel ir ai drive and the differential is os locked providing maximum LH traction The demand drive T ar unit automatically engages when the rear wheels lose trac tion When the rear wheels a api tail nated causal cn iia traction the demand drive unit automatically disengages 2X4 When the 2X4 switch is on the vehicle is in two wheel drive at all times and the dif ferential is locked 28 OPERATION Break In Period The break in period for your new Polaris vehicle is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part will increase the life and performance of your vehicle more than 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 Do not
47. 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 e Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 92 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 follow ing items e Wheel bearings e Electrical components wiring e Radiator e Switches and controls e Transmission seals e Cab and body panels e Brakes e Labels and decals If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container
48. fore ee installation 4 Reverse the procedure for spark plug installation Torque to specification 79 MAINTENANCE Spark Plugs Spark Plug Condition Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect throt tle body carburetor adjustments 80 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your vehicle to a dealer before starting it fol low the steps outlined below 1 2 3 10 11 12 Move the vehicle out of the water mad SWS Turn the fuel valve off Check the air box If water is present dry the air box and replace the filter with a new filter Remove the spark plug
49. g qt i bolt located on the left side of the swing arm Locking Bolts 5 Insert a pin punch through the sprocket hub and into the eccentric housing 72 MAINTENANCE Drive Chain Rear Drive Chain Slack 6 Roll the vehicle forward or back ward to adjust the chain slack to the proper tension See the illustration for proper splice link clip opening position 7 Tighten the eccentric locking bolts to 30 ft Ibs 41 Nm for machines without the hitch and 45 ft lbs 61 Nm for machines with a hitch 8 Tighten the caliper mount bolt to 15 ft Ibs 20 Nm 9 Remove the pin punch Position 10 Roll the vehicle forward checking chain tension in several places around the chain Tip The chain is adjusted correctly when the tightest portion of the chain has approximately 3 8 10mm deflection 11 Position the chain guide to allow 1 8 3 mm clearance and tighten the retaining bolt to 5 ft Ibs 7 Nm 12 Reinstall the chain guard 73 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the
50. gests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 110 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 111 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 112 A Age Restrictions 5 Alp Filtet t o h eda aa uaan aea a 68 All Wheel Drive Switch 21 All Wheel Drive System 28 B Battery sisiers S50rssare es Seeks 86 91 Charging Conventional 90 Charging Sealed 90 91 Fluid Conventional 89 Installation 88 Removal 005 87 Storage mar oads sucs eee eee ee eee 89 BOOts ibis en sie
51. gine sis igrce ide n en 52 Oil Transmission 56 57 Oil and Filter Change 53 55 Oil Level Engine 52 Oil Pump Priming 55 Oil Recommendations 52 Operator Safety 10 15 Override Switch 20 P Parking Brake 25 Parking on an Incline 43 Periodic Maintenance Chart 47 50 Polaris Product List 99 Polishing the Vehicle 93 Pre Ride Checklist 30 PVT Break In 29 PVT Dryines seta aan 85 PVT System 83 85 R Reverse Operation 42 Riding Gear 8 9 S Safety Labels 16 19 No Passenger Warning 18 4X4 Caution s peh a ea aeaa 19 Age 16 Warning 19 Clutch Cover Warning 19 Discretionary Warning 17 General Warning 16 Reverse Override Warning 19 Tire Pressure Load Warning 18 Safety Training gt Severe USE anae tare ees 47 S Side Panel Removal 6l Sidehilling onanan 37 Signal Words o n aaaeeeaa 4 Spark Arrestor n usses 82 Spark Arrestor Requirements 46 Spark Plugs neoaeae 79 80 Spring Preload Rear 63 Starting the Engine 31 32 Steering Assembly 63 Steering Lock 27 Stop Switch 00 20 Stota DE sete w
52. he handlebars are straight 2 View the fluid level through the indicator window eye on the top of the master cylinder The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed Do not overfill Foot Brake 1 Position the vehicle on a level surface 2 The brake fluid reservoir is located either under the seat or near the foot brake View the fluid level in the master cylinder 3 Maintain the fluid level between the minimum and maximum marks Do not overfill 60 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes Both brake systems are self adjusting Brake Inspections Perform the following checks to keep the brake systems in good operat ing condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 59 2 Check the brake systems regularly for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction mate rial is worn to 1 mm 5 Check the security and surface condition of the disc Side Panel Removal Tip Side panel removal may be difficult until the locking tabs and receivers have l 2 3 been snapped and unsnapped a few times Remove the seat Remove the push pins at the front and rear of the side panel G
53. he outer surfaces of the roller must be lubri cated Always inspect the drive chain prior to operating the vehicle Check for damaged or missing o rings or damaged rollers Also check for correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 mm Regularly lubricate the drive chain with Polaris Chain Lube an SAE 80 90 lube or an approved o ring chain spray lube See page 99 for the part numbers of Polaris products A 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 71 MAINTENANCE Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain Measure the chain slack at the tightest of the three positions At this point the chain should have 3 16 3 8 5 mm 10 mm deflection O sss A 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 3 16 3 8 5 mm 10 mm Use the following procedure if adjustment is required 1 Remove the chain guard 2 Loosen the chain guide Pin Punch 3 i o eccentric j ocking bolts T 4 Loosen the caliper mountin
54. he vehicle 24 FEATURES AND CONTROLS Brakes Parking Brake Locking the Parking Brake 1 Place the transmission in gear RD 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the parking brake lock forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position A Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death Always release the parking brake lock before operating Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle F Forward Gear N Neutral R Reverse To shift gears brake to a complete stop When the engine is idling move the lever s to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the vehicle is left unattended always place the transmission in gear and lock the parking brake 25 FEATURES AND CONTROLS Choke The choke assists in startingacold engine Refer to the engine start a j LOS ing procedure on page 31 for cor rect choke and throttle settings during starting Fuel Tank Cap Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel t
55. icci cian tei ore teed ee wees 4 Saf ty 6 4 4 0 c edie SSS e eset ost wees 7 Features and Controls 20 006 20 Operation ce 223 e iaiia eer ie ete 29 Emission Control Systems 46 Maintenance 2 000e eee eee eee 47 Polaris Products 000eeeeeeee 99 Troubleshooting 00000eee eee 100 Specifications 5 nsaw ee eeeee eek es 104 Declaration of Conformity 106 Warranty ia dota ese ddan eae es 107 Maintenance Log 000ee0es 111 INDOX viet eee ee eee tee eae ae 113 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to follow the warnings in this manual can result in serious injury or death This Polaris vehi
56. igned for on road and off road operation It is required that this spark arrestor remain installed and functional when the vehicle is operated Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC 46 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 111 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform the
57. improper alignment see your Polaris dealer for ser vice 62 Steering Assembly MAINTENANCE Check the steering assembly of the vehicle periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Rear Suspension The rear suspension spring pre load and shock compression damping may be adjusted to suit different riding conditions and operator weight Spring Preload 1 Raise and safely support the rear of the vehicle off the ground to allow the suspen sion to fully extend 2 Loosen the jam nut and back it away from the adjusting ring 3 As viewed from the top of the shock turn the adjusting ring clockwise 1 to increase preload Turn the ring counter clockwise 2 to decrease preload 4 Tighten the jam nut firmly against the adjuster ring Locking Ring Adjusting Ring 63 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 Slide the boots off the inline cable adjuster sleeve Loosen the adjuster locknut 2 Turn the adjuster until 1 5 3 mm of freeplay is achieved at the thumb lever Move the throttle lever back and forth several times while adjusting 3 Tighten the lock nut and slide the 1 6 3 mm boots over the cable adjuster until they touch at the midpoint of the adjuster Tip Engine RPM should not increase when steering is turned full left or right R
58. ion and may promote corrosion and oxidation 97 MAINTENANCE Transporting the Vehicle Follow these procedures when lt transporting the vehicle 3 F 1 Stop the engine 2 Place the transmission in gear Pe 3 Lock the parking brake Turn the fuel valve off 5 Secure the fuel cap oil cap and seat 6 Remove the key to prevent loss during transporting 7 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 98 Part POLARIS PRODUCTS Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 95 1 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal 3 8 1 Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 I 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 I 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2870465 Pump for Gallon 3 8 I Jug 2876251 Demand Drive LT Premium Fluid 8 0z 237 ml Coolant 2871323 60 40 Coolant gal 3 8 1 2871534 60 40 Coolant qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z
59. is intended for use on Polaris products only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation 83 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of cen trifugal force decreases reducing the amount of belt pinch This begins to occur at speeds of less than 5 MPH 8 km h due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h the engine would be running at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engage ment speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail If the vehicle will be operated for extended periods below 5 MPH 8 km h or for towing loads we recommend that you install a one tooth smaller counter shaft sprocket to raise the operating RPM far enough above the engagement RPM to reduce heat caused by incomplete engagement Reducing the temperature
60. itting NOTICE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 6 Reinstall the screen fitting and rotate the fitting clock wise a minimum of 2 1 2 turns into the tank threads Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank NOTICE Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs 34 Nm 7 Reattach the oil line 53 MAINTENANCE Oil and Filter Change 8 Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it 9 Lubricate the gasket on the new filter with a film of new engine oil Check to make sure the gasket is in good condition Make sure the gasket from the old filter is not still on the engine 10 Install the new oil filter After the filter contacts the engine Filter surface turn it 1 2 to 3 4 turn by hand 11 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case Tip The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 12 Reinstall the drain plug and torque to 14 ft Ibs 19 Nm 13 Remove the dipstick Add the recommended oil See page 52 Rein stall the dipstick Tip If the sump is not drained add about 1 3 4 quarts initially 14 Place the transmission in neutral Lock the parking brake 15
61. l never back it down the hill Use the K turn to turn around 1 Stop the vehicle Keep your weight uphill 2 Lock the parking brake Leave the transmission in forward gear Turn the engine off 3 Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left Squeeze the brake lever to release the parking brake 5 Slowly release the brake lever and allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake Remount from the uphill side Keep your weight uphill 7 Apply the foot brake Squeeze and release the brake lever to release the parking brake 8 Release the foot brake and drive s owly downhill Control speed with either the hand or foot brake until the vehicle is on level ground 39 OPERATION Driving Through Water Your Polaris vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines 3 Avoid operating oe through deep or fast Maximum Depth flowing water NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in
62. lace spark plugs Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 103 SPECIFICATIONS Scrambler 500 4X4 International Maximum Weight Capacity 275 Ibs 125 kg includes weight of opera tor cargo and accessories Dry Weight 570 Ibs 258 5 kg Fuel Capacity 4 gal 15 1 D Engine Oil Capacity 2 qts 1 9 1 Transmission Oil 32 oz 946 ml Demand Drive Fluid Capacity 9 oz 265 ml Coolant 2 25 qts 2 131 Rear Rack Capacity Accessory 60 Ibs 27 2 kg Maximum Hitch Tongue Weight Capacity 85 Ibs 38 6 kg Rear rack capacity and tongue weight not to exceed 60 Ibs 27 2 kg Hitch Towing Rating 850 Ibs 385 6 kg Unbraked Trailer Towing Capacity 1210 Ibs 549 kg
63. lean external if applicable surfaces gt Cooling hoses 100 H 12M 1000 1600 Inspect for leaks if applicable gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe Spark plug 100 H 12M 1000 1600 Inspect replace as needed p Ignition Timing 100 H 12M 1000 1600 Inspect gt Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc E Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts E Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out Idle speed Adjust as needed E Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed 50 Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 47 Items not listed in the chart should be lubricated at the General Lubrication interval 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 MAINTENANCE Front Gearcase Premi
64. lic Disc All Wheel Foot Brake Foot Activated Hydraulic Disc All Wheel Brake Parking Hydraulic lock all wheel Headlight Single Beam 60w Taillights 12V 8 26W Brake Light 12V 26 9W Battery 12V 14AH Indicators High Beam Turn Signals High Temp Neutral Reverse Jetting Chart ALTITUDE Meters Feet AMBIENT TEMPERATURE Below 40 F 40 F and above Below 5 C 5 C and above 0 1800 0 6000 160 155 1800 3700 6000 12000 152 5 147 5 Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Spring Meters Feet Weight Spring Spring Setting 0 1800 25 52 Blue Green Black 40 0 6000 5632391 7041157 7041782 5131446 2 2 1800 amp above 25 48 Blue Green Black 40 6000 amp above 5630709 7041157 7041782 5131446 2 2 105 DECLARATION OF CONFORMITY Polaris Industries Inc 2100 Hwy 55 Medina MN 55340 U S A Telephone 763 542 0500 We Polaris Industries Inc declare that the vehicles listed below conform to the essential health and safety requirements applicable to off road all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 98 37 EC as amended Machinery Directive EN 1050 hazard analysis CD 77 311 EEC driver perceived noise level 2004 108 EC as amended EMC Directive CISPR 12 2001 CAN CSA C108 4 M92 EN 55012 2002 EN 61000 6 2 2001 PRODUCT IDENTIFICATION
65. n the lower headlight screws to adjust the beam upward or downward or to the left or right 76 MAINTENANCE Lights A Poor lighting can result in loss of control or an accident Lights become dirty during normal operation Wash the headlights and taillights frequently A Hot components can cause burns to skin Allow lamps to cool before servicing Headlamp Replacement When servicing a halogen lamp do not 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 Hold the plastic part of the lamp 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 into the headlight housing and rotate clockwise firmly Tip The bulb must be positioned so the harness installs into the lamp at the bot tom 4 Reinstall the connector to the back of the headlight 77 MAINTENANCE Lights Taillight Brakelight Lamp Replacement l Remove the taillight lens Screw cover mounting screws Cover Remove the lens cover Q and gasket and set aside for reassembly Remove the lamp A Amp Apply dielectric grease f to the socket and install the new lamp Test the taillight brake light for proper opera tion Reinstall the gasket and lens cover Indicator
66. nic Throttle Control sticks in an open position when the operator releases sE the throttle lever A The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 23 FEATURES AND CONTROLS Brakes A Aggressively applying the brakes when backing down a hill may cause rear tipover Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control Read this owner s manual and understand the operation of all brake systems on this vehicle Always use caution whenever applying the brakes Foot Brake The all wheel foot brake is located on the right footrest The foot brake operates both front and rear brakes Press the brake pedal down with your foot to apply the all wheel brakes If the rear wheels begin to skid or slide while using the foot brake reduce brake pressure Hand Brake Lever The hand brake operates both front and rear brakes Squeeze the brake lever toward the han dlebar to apply the all wheel brakes If the rear wheels begin to skid or slide while using the hand brake reduce lever pressure A Operating the vehicle with a spongy brake lever can result in loss of braking which could cause an accident Never operate the vehicle with a spongy feeling brake lever Always contact your dealer for service before operating t
67. on Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Clogged air filter Replace with recommended fuel Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting Possible Rich Fuel Cause Overuse of choke See your dealer Solution Inspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your dealer 102 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Turn fuel valve to reserve refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Overuse of choke Inspect clean and or rep
68. opriate clothing when riding a Polaris vehicle Wear protective clothing for comfort and to reduce the chance of injury Eye Protection Long Sleeves Helmet Gloves Long Pants Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provi
69. or fallen trees 41 OPERATION Driving in Reverse Follow these precautions when operating in reverse Always check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Oo een oS Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 42 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions l m e Stop the engine Place the transmission in gear Lock the parking brake Always block the rear wheels on the downhill side Turn the fuel valve off 43 OPERATION Hauling Cargo A Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO NEVER EXCEED THE MAXIMUM WEIGHT CAPACI
70. p Switch 20 Equipment Modifications 5 7 Exhaust Emission Control System 46 Eye Protection 0 9 F Fluid Brake 59 60 Fluid Demand Drive 58 Foot Brake 0 24 Front Gearcase Fluid 58 Fuel Filter 0 0 0 00 00000 26 Buel Satety son wines Gara tains oie ess 15 Fuel Tank Cap 26 Fuel Valves 0k essa bac ae dee 26 113 INDEX G Gasoline Handling 15 Gear Selector 25 GIOVES i 4 sna haved oe dead teased a 9 H Handlebar Adjustment 69 Hauling Cargo 44 45 Hazard Switch 21 Headlamp Replacement 77 Headlight Beam Adjustment 76 Headlight Switch 21 Helmets 2 0 svc aa ents os 8 Horn Switch 4 21 l Idle RPM Adjustment 70 Immersion 200 81 Indicator Lights 22 J Jetting Chart 00 105 K Key Switch 0 21 KTU eeen ce sels R 39 L 1 ke ne eenei ionda 76 78 Headlamp Replacement 77 Headlight Beam Adjustment 76 Indicator Lamp Replacement 78 Taillight Brakelight Replacement 78 Load Distribution 45 Lubrication Guide 51 M Maintenance Chart 47 50 Mirrors 0 2 0 a 000s ee eee 22 Modifications 537 114 N Noise Emission Control System 46 oO Oil En
71. rasp the rear of the side panel near the rear cab Pull the panel slightly outward downward and rearward to disengage the upper front section To reinstall the side panel align the upper and lower front section with the mating front cab tabs Push the panel upward and forward until the panel is fully seated at the front Lock the rear of the panel into the rear front cab tabs Reinstall the push pins at the front and rear of the side panel 61 MAINTENANCE Toe Alignment A Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 3 6 mm toe out 1 Position the vehicle on a level surface 2 Set the handlebars in a straight ahead position and secure them in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible Make sure both marks are the same distance from the floor 4 Measure the distance between the marks and record the measurement 1 5 Move the vehicle until the chalk marks are at the rear of the tires even with the hub axle center line 6 Measure the distance between the marks and record the measurement 2 7 Subtract measurement 2 from measurement 1 The difference is the vehicle toe out alignment 8 If you discover
72. reme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Turn the fuel valve off whenever the vehicle is stored or parked A Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system For more information about safety contact an authorized Polaris dealer or visit the Polaris web site at www polarisindustries com 15 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND P
73. repair The following items are excluded from warranty coverage in the event of a warranty claim e Spark Plugs e Lubricants such as oil grease etc e Filters e Batteries unless defective e Fuel Cosmetic damage repair Sealants Coolants Hotel fees e Meals e Towing charges Shipping handling fees e Mileage Product pick up delivery e Rentals Loss of product use e Loss of vacation personal time 108 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polari
74. ry 51 Steering steering lock Unlock the steering ensure free 27 operation Tires Inspect condition and pressure 65 Wheels fasteners Inspect ensure fastener tightness 65 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels a Coolant level Ensure proper level 74 Coolant hoses Inspect for leaks Throttle Ensure proper operation a Indicator lights switches Ensure operation 20 Engine stop switch Ensure proper operation 20 Mirrors Adjust for best side rear vision 22 Drive chain Check condition slack lubricate as 71 needed Air filter pre filter Inspect clean 68 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 21 tric grease when lamp is replaced 77 Brake light taillight Check operation apply Polaris dielec 78 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 8 30 OPERATION Starting the Engine A 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 Tip 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 Tip Do not use the choke if starting a warm engine Excessive
75. s A Always travel slowly when operating on unfamiliar terrain Use extra caution A Use caution when operating on rough slippery or loose terrain A Always follow the procedures outlined in this manual for turning See page 34 Never turn sharply at excessive speeds which can lead to vehicle overturn 12 SAFETY Operator Safety A If the vehicle has been involved in an accident always have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not limited to brake throttle and steering systems A Never operate on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 25 Always follow the procedures outlined in this manual for climbing hills See page 36 A Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 38 A Always follow the procedures outlined in this manual for crossing the side of a hill See page 37 Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill See page 39 13 SAFETY Operator Safety A Always follow the procedures outlined in this manual for opera
76. s 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 DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 109 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris dealer authorized to repair Polaris vehicles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris sug
77. se operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour 16 km h Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 47 MAINTENANCE Periodic Maintenance Chart A Improperly performing the procedures marked with a could result in component failure and cause an accident which may result in serious injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Enmission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached firs
78. should be safely tucked away at the front and rear of the battery 10 Reinstall the seat Reto N 88 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge Tip Power plug leads may need to be bent down so that the battery cover can be installed Polaris recommends maintaining battery charge by using a Polaris Bat tery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 99 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery Mark fluid level often Maintain the fluid were a level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 89 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 87 2 Charge the battery with a charging output no larger than 1 10 o
79. ssure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the front panel to access the radiator pressure cap Radiator Cap 2 Remove the pressure cap 3 Ifcoolant is low use a funnel and slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 5 Secure the front panel 6 Fill the coolant recovery bottle to the upper mark on the bottle 7 Check the coolant level in the bottle frequently adding coolant as needed until the level stabilizes 75 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 25 ft 7 6 m 1 Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in neutral 3 Lock the parking brake Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring 5 Start the engine Switch the headlight to high beam 6 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall 7 Tighten or loose
80. t Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Steering Pre Ride vake agusiments as need 7 ed See Pre Ride Checklist gt Front suspension Pre Ride on page 30 gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Headlamp tail Daily Check operation apply lamp dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element gt Brake pad wear 10H Monthly 100 160 Inspect periodically E 48 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Battery 20H Monthly 200 320 Check terminals clean test gt Demand drive fluid 25 H Monthly 250 400 Inspect level change yearly gt Transmission oil 25H Monthly 250 400 Inspect level change yearly gt Engine breather 25 H Monthly 250 400 Inspect clean if needed E filter if equipped gt General 50 H 3M 500 800 Lubricate all fittings pivots lubrication ca
81. t cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items e Wheels and tires e Finished and unfinished surfaces Suspension components e Carburetor Throttle body components e Brake components Engine components Seat components Drive belts e Clutches and components e Hydraulic components Steering components Circuit breakers Fuses e Batteries Electronic components e Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective
82. ting over obstacles See page 41 A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 35 A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 40 A Always follow the procedures outlined in this manual for driving in reverse See page 42 A Always use the size and type of tires specified for your vehicle Maintain the proper tire pressure Never modify this Polaris vehicle through improper installation or use of accessories Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control Avoid sudden turns or swift movement of the handlebars 14 SAFETY Operator Safety A Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking A Never operate this vehicle on a frozen body of water A Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting A Always unlock the steering before starting the engine See page 27 A Handling Gasoline Gasoline is highly flammable and explosive under certain conditions e Always exercise ext
83. top the engine Override quickly Pull the stop Switch Hazard switch up to the RUN Switch position before attempt Horn ing to start the engine Switch Both the main switch and the engine stop switch will shut off all electrical power to the vehicle including lights Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing release the throttle and press the override switch A Pressing the override switch while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override switch The override switch also allows activation of All Wheel Drive in reverse if the AWD switch is on 20 FEATURES AND CONTROLS Switches Headlight Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position D High Beam 4 Low Beam Turn Signal Switch lt gt Push the toggle switch either left or right to activate the corre sponding turn signal light The indicator on the pod will also flash Return the toggle to the center position and push it inward to end the signal Hazard Switch A Push the hazard warning switch to cause all turn signal lights to flash simultaneously Use this feature to alert others of an emer gency or other situation requiring caution Horn Switch box Press the horn switch to sound the horn Main Key Switch
84. tral Lock the parking brake 2 Start the engine Allow it to idle for 30 seconds Stop the engine 3 Remove the dipstick Wipe it dry with a clean cloth Safe Range 4 Reinstall the dipstick completely Make sure the cap is fully seated C to keep the angle and depth of the stick consistent 5 Remove the dipstick and check Add Oil Safe the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 6 Reinstall the dipstick 52 MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine 2 Start the engine Allow it to idle for two to three minutes Stop the engine 3 Place a drain pan under the oil tank Remove the drain plug Allow the oil to drain completely A Hot oil can cause burns to skin Do not allow hot oil to contact skin 4 Reinstall the drain plug with a new sealing washer Torque to specification See Sealing page 52 Washer Tip The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches Screen Fitting 7 Drain 5 Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank Clean the f
85. um Fluid Item Lube Method Engine Oil PS 4 PLUS Performance See page 52 Synthetic 2W 50 Brake Fluid DOT 4 Only See page 59 Drive Chain s O ring chain lube or SAE Lubricate 80 90 Transmission Oil AGL Synthetic Gearcase See page 56 Lube Demand Drive Fluid Demand Drive LT See page 58 Front Prop Shaft Yoke Premium U Joint Lube Grease fittings 3 pumps maximum every 500 miles 800 km before long periods of storage or after pressure washing or submerging Front Prop Shaft Yoke Sa 51 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil Polaris recommends the use of Polaris PS 4 PLUS Performance Syn thetic 2W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation See page 99 for the part numbers of Polaris products A Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Specifications Lubricant Capacity Drain Plug Torque PS 4 PLUS Performance 2 ats 1 9 I 14 17 ft Ibs 19 23 Nm Synthetic 2W 50 4 Cycle Oil Oil Level The oil dipstick is located on the left side of the vehicle 1 Position the vehicle on a level surface Place the transmission in neu
86. 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 If the knob doesn t stay where positioned increase the ten sion by rotating the tension adjusting nut clockwise Tip The variable choke is fully on when Choke the knob is pulled completely out Knob The choke is off when the knob is pushed completely in The choke La can be adjusted gradually depend Adjustin ing on how much choke is needed Nut for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine compo nents 7 Pull the engine stop switch up to RUN 31 OPERATION Starting the Engine 8 9 Do not press the throttle while starting the engine 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 starter and wait five seconds 10 Repeat steps 8 and 9 until the engine starts A Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 11 If a warm engine has cooled to a point where it does not readily start intermittent use of the choke knob pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while

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