Polaris A09BG50AA, A09BA50FA, A09BG50FA User Manual

GENERAL INFORMATION

Model Identification 1.2.......................

Serial Number Location 1.2...................

Replacement Keys 1.3.......................

Publication Numbers 1.3.....................

Paint Codes 1.3.............................

Specifications 1.4--1.5...........................

Standard Torque Specifications 1.6............

Tap Drill Charts 1.7..........................

Specs

Decimal Equivalent Chart 1.7.................

Unit of Measure Conversion Table 1.8..........

Glossary of Terms 1.9--1.10........................

1.1

GENERAL INFORMATION

MODEL IDENTIFICATION

The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

A09BG50AA

Emissions &

Year Designation

Basic Chassis
Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

EH500PLE Single, Liquid Cooled, SOHC 4 Stroke, Electric Start.................

VIN IDENTIFICATION

World Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4XABA

Vehicle Descriptor

50A* P000000

9

Vehicle Identifier

Body Style

Powertrain

Emissions

Engine

Check Digit

Model
Year

Plant No.

Individual Serial No.

* This could be either
a number or a letter

ENGINE SERIAL NUMBER LOCATION

Whenever corresponding about a vehicle, be sure to refer to the engine model number and serial number. This
information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional
number is stamped on the center top of crankcase beneath the cylinder coolant elbow.

UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION

Themachinemodelnumber andserialnumberare
important for vehicle identification. The machine
serial number is stamped on the lower left side of
the frame tube.(B)

A

Front

B

TRANSMISSION I.D. NUMBER
LOCA

TION

1.2

The transmission I.D. number is located
on top of the transmission, right side of
machine.

REPLACEMENT KEYS

Replacement keys can be made from the original
key. To identify which series the key is, take the
first two digits on the original key and refer to the
chart to the right for the proper part number.

Shouldbothkeysbecomelost, ignition switch
replacement is required.

GENERAL INFORMATION

Series # Part Number

20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278

31XX

KEY COVER

P/N 5433534

Key Series
Number

PUBLICATION NUMBERS

Year Model Model No. Owner’s Manual Parts Manual

2009 Scrambler500 4x4 A09BG50AA, FA 9921777 9921778
2009 Scrambler500 2x4 A09BA50FA 9921777 9921778

When ordering service parts be sure to use the correct parts manual.

PAINT CODES

FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.

COLD WEATHER KITS FOR 4 CYCLE ATVS

Engine Heater -- (PN 2871507)

ACCESSORY ENGINE HEATER

1.3

GENERAL INFORMATION

MODEL: 2009 SCRAMBLER 500..........

MODEL NUMBER: A09BG50AA, FA / A09BA50FA.

( 4x4 / Intl’ ) (2x4 Intl’)

ENGINE MODEL: EH50PLE..

Category

Length 75 in./190.5 cm
Width 46 in./116.8 cm
Height 47 in./119.4 cm
Wheel Base 48 in./121.9 cm
Dry Weight 571 lbs./259 kg (4x4)

Gross Vehicle Weight 845 Lbs. / 383 kg (4x4)

Front Rack Capacity

(Accessory)

Rear Rack Capacity

(Accessory)

Tow Capacity 850 lbs./385.9 kg
Tongue Weight 85 lbs./38.6 kg
Body Style Gen III

Dimension / Capacity

571 lbs./259 kg (2x4)

845 Lbs. / 383 kg (2x4)

30 lbs./13.6 kg

60 lbs./27.2 kg

1.4

NOTE: 4x4 Model Shown

MODEL: 2009 SCRAMBLER 500..........

MODEL NUMBER: A09BG50AA, FA / A09BA50FA.
ENGINE MODEL: EH50PLE..

Engine

Platform Fuji Single Cylinder
Engine Model Number EH500PLE
Engine Displacement 499cc
Number of Cylinders 1
Bore & Stroke 92 x 75 mm

3.6248I x 2.955I
CompressionRatio 10.2:1
Compression Pressure 70--90 psi w/decompressor
Engine Idle Speed 1200Rpm ± 100
Engine Max Operating Rpm 6500 Rpm ± 200
Cooling System / Capacity Liquid -- 2.25 qt / 2.1 ltr
Overheat Warning HOT Indicator
Lubrication PressurizedDry Sump
Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr
Exhaust System Single Pipe

Carburetion

Carburetor model Mikuni BST 40mm
Main Jet 155
Pilot Jet 40
Pilot Air Jet 160
Jet Needle -- Clip Position 6H25--94--3
Needle Jet Y--0M (896)
Pilot Screw 2 Turns Out

(Set at factory, will vary on each vehicle)

Float Height 13 ± 1 mm / 0.51 ± 0.40“
Fuel Delivery Fuel Pump
Fuel Capacity / Requirement 3.5 gal US / 13.2 ltr

87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 250 w @ 5000 RPM
Voltage Regulator 3--Phase-- LR--39
Lights : Head(Twin) 30 / 30 watts

Brake 8.26 watts

Tail 26.9 watts
Ignition System CDI Ignition
RPM Limit 6600 RPM
Ignition Timing 30° BTDC @ 5000 RPM ± 250
Spark plug / Gap BKR6E/ .036 in./0.9 mm
Battery / Model / Amp Hr Low Maintenance 14 Amp Hr
Circuit Breakers Solid State in PDM
Starting Electric

GENERAL INFORMATION

Drivetrain

Transmission Type H/N/Rev
Transmission Capacity 32oz. / 945ml
Front AWD Hub Capacity 2.5 oz. / 75ml
Front Gearcase Capacity 4oz./118ml
Gear Ratio : Low

Rev

High

Front Drive

Rear Drive / Chain Pitch
Chain Type 520 O--ring
PVT Type / Belt Non--EBS / 3211091

Steering / Suspension

Front Suspension / Shock A--arm / MacPherson Strut
Front Travel 8.2 in. / 20.83 cm
Rear Suspension / Shock Progressive Rate Swing Arm

Twin Tube Gas Charged
Rear Travel 10.5 in. / 26.67 cm
Ground Clearance 5.5 in. / 13.97 cm
Shock Preload Adjustment

Front / Rear

Front --Non Adjustable.

Rear -- Cam Adjuster
Turning Radius 83 in. / 210.8 cm unloaded
Toe Out 1/8 -- 1/4 in / 3 -- 6.35 mm

Wheels / Brakes

Wheel Size / Pattern -- Front Steel 23x7--10 / 4--156
Wheel Size / Pattern -- Rear Steel 22x11--10 / 4--102
Front Tire Size 23x7--10
Rear Tire Size 22x11--10
Recommended Air Pressure

F/R
Brake -- Front Dual Hydraulic Disc
Brake -- Rear Single Hydraulic Disc

JETTING CHART

AMBIENT TEMPERATURE

Below 40°F

Below 5°C

160

152.5

Meters

(Feet)

Altitude

(0--6000)

above 1800

(above 6000)

0--1800

CLUTCH CHART

Shift

Weight

10 WH

PN 5630710

10 RH

PN 5630709

Spring

Blu/Grn

PN 7041157

Blu/Grn

PN 7041157

Meters

(Feet)

Altitude

0--1800

(0--6000)

1800--3700

(6000--12000)

n/a

4.74:1

3.06:1
2:1

13/36 76 Pitch

4 psi Front

3 psi Rear

+40°Fto+80°F

Drive

Driven

Spring

Silver

PN 7041499

Silver 1--1

PN 7041499

+5°Cto+28°C

155

147.5

Driven

Helix
40_

PN 5131446

40_

PN 5131446

1--1

1.5

GENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS

Thefollowing torquespecificationsare tobeused as a generalguideline. FOR SPECIFICTORQUE VALUESOF
FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering,

suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

T orque in. lbs. (Nm)

#10 - 24 27 (3.1) 43 (5.0) 60 (6.9).............. ................ ..............

#10 - 32 31 (3.6) 49 (5.6) 68 (7.8).............. ................ ..............

T o rque ft. lbs. (Nm)*

1/4 - 20 5 (7) 8 (11) 12 (16).............. .................. ................

1/4 - 28 6 (8) 10 (14) 14 (19).............. .................. ..............

5/16 - 18 11 (15) 17 (23) 25 (35).............. ................ ..............

5/16 - 24 12 (16) 19 (26) 29 (40).............. ................ ..............

3/8 - 16 20 (27) 30 (40) 45 (62).............. ................ ..............

3/8 - 24 23 (32) 35 (48) 50 (69).............. ................ ..............

7/16 - 14 30 (40) 50 (69) 70 (97).............. ................ ..............

7/16 - 20 35 (48) 55 (76) 80 (110).............. ................ ..............

1/2 - 13 50 (69) 75 (104) 110 (152).............. ................ .............

1/2 - 20 55 (76) 90 (124) 120 (166).............. ................ .............

Metric

6 x 1.0 72-78 In. lbs. 8 x 1.25 14-18 ft. lbs. 10 x 1.25 26-30 ft. lbs..... ......

1.6

GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size/Drill Size Thread Size/Drill Size

#0-80 3/64
#1-64 53
#1-72 53
#2-56 51
#2-64 50
#3-48 5/64
#3-56 45
#4-40 43
#4-48 42
#5-40 38
#5-44 37
#6-32 36
#6-40 33
#8-32 29
#8-36 29
#10-24 24
#10-32 21
#12-24 17
#12-28 4.6mm
1/4-20 7
1/4-28 3
5/16-18 F
5/16-24 I
3/8-16 O
3/8-24 Q
7/16-14 U
7/16-20 25/64

1/2-13 27/64
1/2-20 29/64
9/16-12 31/64
9/16-18 33/64
5/8-11 17/32
5/8-18 37/64
3/4-10 21/32
3/4-16 11/16
7/8-9 49/64
7/8-14 13/16
1-8 7/8
1-12 59/64
1 1/8-7 63/64
1 1/8-12 1 3/64
11/4-7 17/64
1 1/4-12 1 11/64
11/2-6 111/32
1 1/2-12 1 27/64
13/4-5 19/16
1 3/4-12 1 43/64
2-4 1/2 1 25/32
2-12 1 59/64
2 1/4-4 1/2 2 1/32
21/2-4 21/4
23/4-4 21/2
3-4 2 3/4

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal

Equiva-

lent

3x.50
3x.60
4x.70
4x.75
5x.80
5x.90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75

#39
3/32
#30
1/8
#19
#20
#9
16/64
J
17/64
5/16
5/16
11/32
R
3/8
13/32
13/32

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3125

0.3437

0.339

0.375

0.406

0.406

Nearest

Fraction

3/32
3/32
1/8
1/8
11/64
5/32
13/64
15/64
9/32
17/64
5/16
5/16
11/32
11/32
3/8
13/32
13/32

DECIMAL EQUIVALENTS

1/64 .0156................

1/32 .0312 1 mm = .0394″........... ...

3/64 .0469................

1/16 .0625...........

5/64 .0781 2 mm = .0787″................ ...

3/32 .0938...........

7/64 .1094 3 mm = .1181″.............. ...

1/8. .1250...

9/64 .1406................

5/32 .1563 4 mm = .1575″........... ...

11/64 .1719...............

3/16 .1875 5 mm = .1969″........... ...

13/64 .2031...............

7/32 .2188...........

15/64 .2344 6 mm = .2362″............... ...

1/4 .25....

17/64 .2656 7 mm = .2756″............... ...

9/32 .2813...........

19/64 .2969...............

5/16 .3125 8 mm = .3150″........... ...

21/64 .3281...............

11/32 .3438 9 mm = .3543″.......... ...

23/64 .3594...............

3/8 .375....

25/64 .3906 10 mm = .3937″............... ...

13/32 .4063.........

27/64 .4219 11 mm = .4331″............... ...

7/16 .4375...........

29/64 .4531...............

15/32 .4688 12 mm = .4724″......... ...

31/64 .4844...............

1/2 .5 13 mm = .5118.... ..............

33/64 .5156...............

17/32 .5313.........

35/64 .5469 14 mm = .5512″............... ...

9/16 .5625...........

37/64 .5781 15 mm = .5906″............... ...

19/32 .5938.........

39/64 .6094...............

5/8 .625 16 mm = .6299″.... ............

41/64 .6406...............

21/32 .6563 17 mm = .6693″......... ...

43/64 .6719..............

11/16 .6875..........

45/64 .7031

23/32 .7188.........

47/64 .7344 19 mm = .7480″............... ...

3/4 .75....

49/64 .7656...............

25/32 .7813 20 mm = .7874″......... ...

51/64 .7969...............

13/16 .8125 21 mm = .8268″......... ...

53/64 .8281...............

27/32 .8438.........

55/64 .8594 22 mm = .8661″............... ...

7/8 .875....

57/64 .8906 23 mm = .9055″............... ...

29/32 .9063.........

59/64 .9219..............

15/16 .9375 24 mm = .9449″......... ...

61/64 .9531...............

31/32 .9688 25 mm = .9843......... ...

63/64 .9844...............

11.0.....

18 mm = .7087″............... ...

1.7

GENERAL INFORMATION

CONVERSION TABLE

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =in.lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 =Nm
in. lbs. x .0115 =kg-m
Nm x .7376 = ft.lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 =in.lbs.
kg-m x10 =Nm
in. x 25.4 =mm
mm x .03937 =in.
in. x2.54 =cm
mile (mi.) x1.6 =km
km x .6214 = mile (mi.)
Ounces (oz) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz)
lb. x .454 =kg
kg x 2.2046 =lb.
Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)
Imperial pints (Imp pt) x 0.568 = Liters (l)
Liters (l) x1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x 1.137 = Liters (l)
Liters (l) x0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)
US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)
US quarts (US qt) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

π (3.14) xR2x H (height) = Cylinder Volume

°Cto°F: 9 (°C + 40) ÷ 5-40=°F
°Fto°C: 5 (°F + 40) ÷ 9-40=°C

1.8

GENERAL INFORMATION

GLOSSARY OF TERMS

ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm). Polaris measures chain length in number of

pitches.

CI: Cubic inches.
Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven

clutch.
ClutchOffset: Drive and drivenclutchesareoffsetso thatdrivebelt will stay nearlystraightasit movesalongtheclutch

face.
Clutch Weights: Three levers in the driveclutch which relative to theirweight, profile and engine RPMcause thedrive

clutch to close.

Condenser/Capacitor: A storage reservoir for DC voltage.
Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported

between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and

out-of-round in the cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn’t complete.
Electrical Short: Short circuit. Anelectrical circuit which is completed before the current reaches the intended load.

(i.e. a bare wire touching the chassis).

End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
HP: Horsepower.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

2

kg/cm
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
lorltr: Liter .

lbs/in
Left Side: Always referred to based on normal operating position of the driver.

: Kilograms per square centimeter.

2

: Pounds per square inch.

1.9

GENERAL INFORMATION

GLOSSARY OF TERMS

m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

windings. Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040″.
Nm: Newton meters.
OD: Outside diameter .
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM

increases.

Reservoir T ank: Thefill tank in the liquid cooling system.
Resistance: Inthemechanicalsense,frictionorload. Intheelectricalsense, ohms. Bothresult inenergyconversionto

heat.

Right Side: Always referred to based on normal operating position of the driver.
RPM: Revolutions per minute.
Secondary Clutch: Driven clutch on chaincase or jackshaft.
SeizedPiston: Gallingofthesidesof a piston. Usuallythereis a transferofaluminumfromthe pistonontothecylinder

wall. Possible causes: 1) improper lubrication; 2)excessive temperatures; 3)insufficient piston clearance; 4) stuck
piston rings.

Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the

circuit.

Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.

1.10

Periodic Maintenance Chart 2.2-2.5...............

Lubricant and Maintenance Product Numbers 2.6

Pre-Ride Inspection 2.7......................

Pure Polaris Products for Your ATV 2.8.........

Lubrication Charts 2.9-2.11........................

Front Gearcase Lubrication 2.11................

Transmission Lubrication 4x4 2.12..............

MAINTENANCE

Transmission Linkage Adjustment (H/L/R) 2.13-2.14...

Throttle Operation / Choke Adjustment 2.14......

Carburetor Adjustments 2.14--2.16...................

ETC Switch Operation 2.16-2.17....................

Fuel System 2.17-2.18.............................

Compression Test 2.19........................

Battery Maintenance 2.19-2.21......................

Electrical 2.21-2.22................................

Coolant System Maintenance 2.23..............

Air Filter Service 2.24--2.25.........................

Air Box Sediment Tube Service 2.25............

Breather Filter 2.25...........................

Recoil Housing 2.26...........................

PVT Drying 2.26............................

Oil Change/Filter 2.26-2.29.........................

Valve Clearance 2.29-2.30.........................

Steering and Toe Alignment 2.30-2.32...............

Front Hub Maintenance (AWD Models) 2.32--2.33.....

Exhaust System Maintenance 2.33--2.34.............

Brake System Service 2.34-2.35....................

Drive Chain and Sprocket Service 2.35-2.36..........

Suspension Service / Controls 2.37-2.39.............

Wheel Removal / Installation 2.39-2.40...............

Tire Inspection 2.40...........................

2.1

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.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment

procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle
speedofapproximately10 milesperhour. Vehiclessubjectedto severeuse mustbe inspectedandservicedmore
frequently.

Severe Use Definition

G Frequent immersion in mud, water or sand
G Racing or race-style high RPM use
G Prolonged low speed, heavy load operation
G Extended idle
G Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting
in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if
it continues to rise, discontinue use and determine the cause or see your dealer.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

H= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed

by an authorized Polaris dealer.

"= SEVERE USE ITEM ----If vehicle is subjected to severe use, decrease interval by 50%

(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm
use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is
required under these conditions. Fluid changes, cable, chain and chassis lubrication are required more
frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention
to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and
determine cause.)

E= Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING: Improperly performing the procedures marked with a

to serious injury or death. Have an authorized Polaris dealer perform these services.

J could result in component failure and lead

2.2

MAINTENANCE AND LUBRICATION

j

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

J

Steering

"

Front suspension

"

Rear suspension
Tires

"

Brake fluid level

"

Brake lever travel
Brake systems
Drive Chain
Wheels/fasteners
Frame fasteners

"

Engine oil level

E

"

Air filter, pre-filter

E

"

Air box sediment

E

tube
Coolant

--

--

--

--

--

--

--

--

--

--

--

--

--

--

Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride

Daily
Daily

Daily

--

--

--

--

--

--

--

--

--

--

--

--

--

--

Make adjustments as needed.

Inspect; clean often
Drain deposits when visible

Check level daily, change coolant every 2 years

(if applicable)
Headlamp/tail

lamp

"

Air filter,

E

main element
Recoil housing

--

--

--

Daily
Weekly
Weekly

--

Check operation; apply dielectric grease if re­placing

--

--

Inspect; replace as needed
Drain water as needed, check often if operating

in wet conditions

"

Brake pad wear 10 H Monthly 60 (100) Inspect periodically

J

Battery 20 H Monthly 125 (200) Check terminals; clean; test

"

Front gearcase oil

25 H Monthly 155 (250) Inspect level; change yearly

(if equipped)

"

Middle gearcase

25 H Monthly 155 (250) Inspect level; change yearly

oil (if equipped)

"

Rear gearcase oil

25 H Monthly 155 (250) Inspect level; change yearly

(if equipped)

"

Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly

Remarks

" Perform these procedures more often for vehicles
subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these
services.

2.3

MAINTENANCE

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

"

Engine breather

E

filter (if equipped)

"

Engine oil change

E

(break-in)

"

General

25 H Monthly 155 (250) Inspect; replace if necessary
25 H 1M 155 (250) Perform a break-in oil change at one month
50 H 3M 310 (500) Lubricate all grease fittings, pivots, cables, etc.

lubrication
Shift Linkage 50 H 6M 310 (500) Inspect, lubricate, adjust

J

Steering 50 H 6M 310 (500) Lubricate

"

Front suspension 50 H 6M 310 (500) Lubricate

"

Rear suspension 50 H 6M 310 (500) Lubricate
Carburetor float

50 H 6M 310 (500) Drain bowl periodically and prior to storage

bowl

J

Throttle Cable/

E

ETC Switch

J

Choke cable 50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary

E
E

Carburetor air

50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary

50 H 6M 310 (500) Inspect ducts for proper sealing/air leaks
intake ducts/
flange

Drive belt 50 H 6M 310 (500) Inspect; adjust; replace as needed
Cooling system

(if applicable)

50 H 6M 310 (500) Inspect coolant strength

seasonally; pressure test
system yearly

"

Engine oil change 100 H 6M 620

E

"

Oil filter change 100 H 6M 620

E

"

Oil tank vent hose 100 H 12 M 620

E

J

Valve clearance 100 H 12 M 620

E

(1000)
(1000)
(1000)
(1000)

Perform a break-in oil change at 25 hours/one
month

Replace with oil change
Inspect routing, condition
Inspect; adjust

" Perform these procedures more often for vehicles
subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these
services.

2.4

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

J

Fuel system 100 H 12 M 620

E

J

Fuel filter 100 H 12 M 620

E

"

Radiator

100 H 12 M 620

(if applicable)

"

Cooling hoses

100 H 12 M 620

(if applicable)

"

Engine mounts 100 H 12 M 620
Exhaust muffler/

100 H 12 M 620

pipe

J

Spark plug 100 H 12 M 620

E

J

Ignition Timing 100 H 12 M 620

E

"

Wiring 100 H 12 M 620

J

Clutches (drive

100 H 12 M 620

and driven)

J

Front wheel

100 H 12 M 1000

bearings

J

Brake fluid 200 H 24 M 1240
Spark arrestor 300 H 36 M 1860

E

Idle speed

J

Toe adjustment

"

Auxiliary brake

J

Headlight aim

--

--

--

--

(Km)

(1000)

(1000)
(1000)
(1000)
(1000)
(1000)
(1000)
(1000)
(1000)

(1000)
(1600)
(2000)
(3000)

Remarks

Check for leaks at tank cap, lines, fuel valve, fil­ter, pump, carburetor; replace lines every two
years

Replace yearly
Inspect; clean external

surfaces
Inspect for leaks

Inspect
Inspect
Inspect; replace as needed
Inspect
Inspect for wear, routing,

security; apply dielectric grease to connectors
subjected to water, mud, etc.

Inspect; clean; replace worn parts
Inspect; replace as needed
Change every two years
Clean out
Adjust as needed

Inspect periodically; adjust when parts are re­placed

Inspect daily; adjust as needed
Adjust as needed

" Perform these procedures more often for vehicles
subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these
services.

2.5

MAINTENANCE

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)
2871281 Engine Oil (Quart)Premium 4 Synthetic

0W-- 40 (4-- Cycle) (12 Count)

2871844 Engine Oil (Gallon) Premium 4 Synthetic

0W-- 40 (4-- Cycle) (4 Count)

2871567 Engine Oil (16 Gallon) Premium 4

Synthetic 0W--40 (4 --Cycle)

Gearcase / Transmission Lubricants

2873602 Premium Synthetic AGL Gearcase Lube

(12 oz. bottle)(12 Count)

2873603 Premium Synthetic AGL Gearcase Lube

(1 Gal.) (4 Count)

2876160 Premium ATV Angle Drive Fluid

(32 oz.) (12 Count)

2872276 Premium ATV Angle Drive Fluid

(2.5 Gal) (2 Count)

2870465 Oil Pump for 1 Gallon Jug
2871654 Premium Demand Drive Hub Fluid

(8 oz.) (12 Count)

Grease / Specialized Lubricants

2871322 Premium All Season Grease

(3 oz. cartridge)(24 Count)

2871423 Premium All Season Grease

(14 oz. cartridge)(10 Count)

2871460 Starter Drive Grease (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871312 GreaseGun Kit
2871329 Dielectric Grease (Nyogelt)

Coolant

2871323 60/40 Coolant (Gallon)(6 Count)
2871534 60/40 Coolant (Quart) (12 Count)

Part No. Description

Additives / Sealants / Thread Locking Agents /

Misc.

2874275 Loctitet Primer N, Aerosol
2871956 Loctitet Thread Sealant 565

(50 ml.)(6 Count)

2871949 Loctitet Threadlock 242

(50 ml.) (10 Count)

2871950 Loctitet Threadlock 242

(6 ml.)(12 Count)

2871951 Loctitet Threadlock 262

(50 ml.) (10 Count)

2871953 Loctitet Threadlock 271

(6 ml.)(12 Count)

2871954 Loctitet Threadlock 271

(36 ml.)(6 Count)

2870587 Loctitet 518 Gasket Eliminator/ Flange

Sealant (50 ml.) (10 Count)

2871326 Premium Carbon Clean

(12 oz.) (12 Count)

2870652 Fuel Stabilizer (16 oz.) (12 Count)
2871957 Black RTV Silicone Sealer

(3 oz. tube) (12 Count)

2871958 Black RTV Silicone Sealer

(11 oz. cartridge) (12 Count)

2870990 DOT3 Brake Fluid (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)

NOTE: The number count indicated by each part

number in the table above indicates the number of
units that are shipped with each order.

NOTE: Each item can be purchased separately at
your local Polaris dealer.

POLARIS LUBRICANT SYMBOL IDENTIFICATON

AGL

Polaris DOT 3
Brake Fluid

Polaris Sythetic
Gearcase Lube

AGL

U--Joint

Polaris U--Joint Lube

2.6

0W/40

Polaris Sythetic
OW-- 40 Oil

DHF

Polaris Demand
Drive Hub Fluid

Polaris All Season Grease

ADF

Polaris ATV
Angle Drive Fluid

MAINTENANCE

PRE-RIDE / DAILY INSPECTION

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

G Tires - check condition and pressures
G Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
G All brakes - check operation (includes auxiliary brake)
G Throttle - check for free operation
G Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
G Engine stop switch - check for proper function
G Wheels - check for loose wheel nuts
G Air cleaner element - check for dirt or water; clean or replace
G Steering - check for free operation, noting any unusual looseness in any area

G Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
G Engine coolant - check for proper level at the recovery bottle

COLD WEATHER KITS FOR 4 STROKE ATVS

Engine Heater -- (PN 2871507)

ACCESSORY ENGINE HEATER

2.7

MAINTENANCE

POLARIS LUBES/FLUIDS FOR SCRAMBLER 500 MODELS

Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer.

2873554 -- ATV Oil Change Kit

-- Oil Filter & 3 Qts. of 0W--40 oil

-- Reservoir Gasket

--DrainPlugGasket

-- Instruction Sheet

2.8

LUBRICATION

MAINTENANCE

Ill.

Item Lube Rec. Method Frequency*

#

1 Engine Oil Polaris 0W--40

Synthetic

2 Transmission Polaris AGL

Gearcase Lubri­cant

3 Brake Fluid Polaris DOT 3

Brake Fluid

4 DriveChain Polaris Chain

Lube or O-Ring
chain lube

5 FrontGear-

case

0W/40

ATV Angle
Drive Fluid

Dipstick

Filter

1. Engine Oil and Filter

Add oil to proper level. Change after 1st month, 6 months or 100

hours thereafter; Change more often (25-50
hours) in extremely dirty conditions, or short
trip cold weather operation.

Fill to bottom of fill hole. Approx. 32
oz.

Fill master cylinder reservoir to in­dicated level inside reservoir.

Apply to chain link plates and roll­ers.

Add to bottom of fill plug threads. Change annually©

AGL

Change annually ©

As required. Change fluid every 2 years.

As required*

Fill Plug

2. Transmission Fill Plug

Parking Brake Lock

3. Brake Fluid

Reservoir

4. Rear Drive Chain

Fill Plug

ADF

5. Front Gearcase

2.9

MAINTENANCE

LUBRICATION, CONT.

7. Tie Rod End

9. Swing Arm Bushings

10. Rear Concentric Housing

5. AWD Hubs

6. BallJoint

Ill.

#

5 AllWheel Drive

Hubs -- ATVs

6 Ball Joint Polaris All Season

7 Tie Rod Ends Polaris All Season

8 PropshaftYoke Premium U-Joint

9 Swing Arm Bush-

ings

10 Eccentric Housing Polaris All Season

Item Lube Rec. Method Frequency*

Polaris Demand
Drive Hub Fluid

Grease¢

Grease¢

Grease
Polaris All Season

Grease¢

Grease¢

4 or 8 O’clock position-

(end view)

Remove filler hole screw in hubs. Rotatewheels to
4 or 8 O’clock position. If lubricant is not visible add
until it flows from filler hole. Reinstall screw.

Locate grease fitting on back side of struts and
grease with grease gun.

Lift boot. Clean away dirt and grease. Apply fresh
grease by hand and reassemble.

Locate fittings and grease - 3 pumps maximum Annually©

Locate grease fitting on swing arm and grease with
grease gun.

Locate grease fitting on eccentric housing and
grease with grease gun.

DHF

8. Propshaft Yoke

(3 pumps max.)

Semi-annually

¡

Semi-annually

¡

Semi-annually

¡

Semi-annually

¡

Annually©

* More often under severe use, such as operated in water or under severe loads.

¡ Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)

More often under severe conditions (operating in water or hauling heavy loads)

© Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

More often under severe conditions (operating in water or hauling heavy loads)

¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or

Mobilegrease Special

2.10

MAINTENANCE

LUBRICATION / GREASE
POINTS

As shown on Page 2.7, there are only five grease
zerks on the Trail Blazer, two front ball joints, two on
theswingarepivots, andoneontherearaxlehousing.

Swing Arm Pivot

Each Side

G Be sure vehicle is level before

proceeding.

G Check vent hose to be sure it is

routed properly and unobstructed.

G The correct gearcase lubricant to

use is ATV Angle Drive Fluid (PN

2871653), or an equivalent lubricant
with a GL5 rating.

Make sure vent is unobstructed

Fill plug

ADF

Drain plug

Ball Joint Zerk

Each Side

Ball Joint Zerk

FRONT GEARCASE
LUBRICATION

The gearcase lubricant level should be checked and
changed in accordance with the maintenance
schedule.

(4X4)

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:

ATV Angle Drive Fluid (PN 2871653)

Capacity: 4.0 Oz. (120ml.)

Drain Plug / Fill Plug T orque:

14 ft. lbs. (19.4 Nm)

To check the level:

1. Remove the fill plug. Inspect the level of lube.
AddATVAngleDriveFluid(PN 2871653) until
level of fluid is flush with the bottom of the fill plug
threads.

To change lubricant:

1. Remove gearcase drain plug located on the
bottom and drain oil. Catch and discard used oil
properly.

2. Cleanand reinstall drainplug using a newsealing
washer.

3. Remove fill plug.

4. Add proper amount of lubricant.

5. Install fill plug.

6. Check for leaks.

2.11

MAINTENANCE

TRANSMISSION LUBRICATION

The transmission lubricant level should be checked
and changed in accordance with the maintenance
schedule.

G Be sure vehicle is level before

proceeding.

G Check vent hose to be sure it is

routed properly and unobstructed.

G Follow instructions on following

pages to check / change
transmission lubricant.

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris AGL Gearcase Lubricant (PN 2873603)

(Gallon) (PN 2873602) (12 oz.)

Capacity: 4x4 -- 32 oz. / 945 ml

Drain Plug / Fill Plug T orque:

14 ft. lbs. (19.4 Nm)

To change lubricant:

1. Removepropshaft shieldfromthe rightsideof the
vehicle.

2. Remove transmission drain plug drain the oil.
Catch and discard used oil properly.

3. Clean and reinstall the drain plug with a new
sealing washer. Torque to specification.

4. Remove fill plug.

5. Add Polaris AGL Gearcase Lubricant (PN

2873602) to proper level as described above.

6. Check for leaks.

7. Reinstall propshaft shield.

Right Side View of A TV

4x4 Models
To check the level:

1. Removepropshaft shieldfromthe rightsideof the
vehicle.

2. Remove fill plug and visually inspect the oil level.
Level is correct when it reaches the bottom of the
fill hole as shown below.

Oil Level

AGL

15/8″

View From Front

Transmission Fill Plug

Do not fill to bottom

of fillplug threads

2.12

MAINTENANCE

TRANSMISSION GEARSHIFT
LINKAGE
PRELIMINARY

Correctly Tightened

Jam Nut

G Ifshiftingproblems areencountered,

thetransmission linkagemayrequire
adjustment.

G Visually check for contact of shift

lever to shifter opening in the front
fender. Ensure shift linkage or shift
lever is not contacting the frame or
exhaust components.

G Tightenshiftlinkage rodendjam nuts

properly after adjustment. You
should be able to rotate the linkage
rod between 1/8 and 1/4 turn after
both jam nuts are tight.

G The transmission shift linkage

should be periodically inspected for
wear and parts replaced as required
to remove excess play from shift
linkage.

G Refer to Transmission chapter for

more information.

NOTE: Therod end must be held whentighteningthe
jam nut to prevent damage to the rod end.

ADJUSTMENT,

INSPECTION

Linkage rod will rotate

1/8 -1/4 turn if rod ends

are tightened properly.

Parallel

Incorrectly Tightened

Jam Nut

SHIFT LINKAGE
ADJUSTMENT

1. Inspect shift linkage tie rod ends, clevis and pivot
bushings and replace if worn or damaged.

2. Place gear selector in neutral.

3. Loosen rod end adjuster jam nuts (A) on both
ends of linkage rod. NOTE: The jam nut with
yellow plating is Left Hand thread.

Gear Selector

Arm

Jam Nuts (A)

Linkage Rod

Ill. 1

4. Turn linkage rod (A) to shorten or lengthen rod
until the shift lever is centered on hole in the fender.

A

2.13

MAINTENANCE

5. Hold rod end parallel to mounting surface and
tighten jam nuts securely.

Center Lever

In Slot

THROTTLE OPERATION

Check for smooth throttle opening and closing in all
handlebar positions. Throttle lever operation should
be smooth and lever must return freely without
binding.

PILOT SCREW

Thepilotsystem suppliesfuelduringengine operation
with the throttle valve closed or slightly opened. The
fuel/air mixture is metered by pilot screw and
discharged into the main bore through the pilot outlet.

CAUTION:

The pilotscrew is calibratedatthe factoryto meetEPA/ CARB
regulationsfor air qualitystandards and is sealed with a brass
plug to prevent tampering. Removal of the tamper proof plug
is not permitted. For service purposes, cleaning of the pilot
circuitcan be done only by a certifiedrepairshop to ensure air
quality standards are not exceeded.

Pilot Screw location

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If idle
speed increases at any point inthe turningrange,
inspect throttle cable routing and condition. If
cable is routed properly and in good condition,
repeat adjustment procedure.

5. Replace the throttle cable if worn, kinked, or
damaged.

Brass Plug Installed

Brass Plug Removed

2.14

MAINTENANCE

PILOT SCREW ADJUSTMENT

FRONT
(Engine)

Pilot Screw

View -- Right Cover Panel Removed

6. Slowly turn mixture screw counterclockwise until
idle speed increases to maximum RPM.
Continue turning counterclockwise until idle RPM
begins to drop.

7. Center the pilot screw between thepoints in Step
5 and 6.

8. Re adjust idle speed if not within specification.

IDLE SPEED ADJUSTMENT

1. Start engine and warm it up thoroughly.

CV Carburetor

Pilot Screw

1. Start engine and warm it up to operating
temperature (about 10 minutes).

2. Turnpilot screw in (clockwise) until lightly seated.
Turn screw out the specified number of turns.
NOTE: Do not tighten the pilot screw forcefully
against the seat or the screw and/or seat will be
permanently damaged.

The pilot screw is set at the factory.
Each carburetor will have a slightly differ­ent pilot screw setting, the adjustments
below are the recommended settings, the
settings may differ from these recommen­dations.

Pilot Screw Adjustment:
Scrambler 500 -- 2 Turns Out

3. Connect an accurate tachometer that will read in
increments of + or -- 50 RPM such as the PET
2100DX (PN 8712100DX) or the PET 2500 (PN

8712500).

4. Set idle speed to 1200 RPM. Always check
throttle cable freeplay after adjusting idle speed
and adjust if necessary.

5. Slowly turn mixture screw clockwise using the
pilot screw wrench until engine begins to miss.

Idle Screw

Idle Speed:

1200 +/-- 200 RPM

2. Adjust idle speed by turning the idle adjustment
screw in (clockwise) to increase or out
(counterclockwise) to decrease RPM. (Refer to
Ill. at right).

NOTE: Adjusting theidle speed affects throttle cable
freeplay and electronic throttle control (ETC)
adjustment. Always check throttle cable freeplay
after adjusting idle speed and adjust if necessary.

2.15

MAINTENANCE

THROTTLE CABLE /
ELECTRONIC
CONTROL (ETC

THROTTLE

SWITCH)

ADJUSTMENT

1. Slide the boots off inline cable adjuster sleeve.
Loosen adjuster locknut.

2. With handlebars centered and wheels pointing
forward, turn adjuster sleeve until 1/16″ -1/8″
freeplay is achieved at the thumb lever. After
making any adjustment, “flip” the lever slightly to
confirm adjustment.

Boot

Adjuster

Sleeve

Direction

of travel

3. Tighten locknut and slide boots over cable
adjuster until they touch at the middle point of the
adjuster.

4. Withengine running, turn the handlebars fromfull
left to full right with transmission in neutral.
Engine RPM should not change and the engine
should not die. If either of these occur, return to
the first step.

1/16″ -1/8″

Freeplay

Lock-

nut

Boot

THROTTLE OPERATION

To remove the ETC cover:

1. Use a medium flat blade screwdriver and insert
blade into the pockets of the cover starting on the
#1 position.

3

6

5

2. Twistscrewdriver slightly while lifting onthecover
to release snap.

3. Repeat procedure at the other five locations as
shown. NOTE: Do not attempt to remove cover
until all latch points are released.

Check for smooth throttle opening and closing in all
handlebar positions. Throttle lever operation should
be smooth and lever must return freely without
binding. Replace the throttle cable if worn, kinked, or
damaged.

2

1

4

2.16

NOTE: When replacing the cover, check for correct
placement of cover O-ring.

MAINTENANCE

CHOKE (ENRICHER)
ADJUSTMENT

Boot

If the choke knob does not stay out when pulled,
adjust the choke tension by tightening the tensioner
located under the rubber boot between the choke
knob and nut. Firmly grasp the rubber boot and
tighten until thechoke slides freely but stays out when
pulled.

Verify free play of 1/16--3/16” (1.6--4.76 mm) and
smooth operation of choke cable.

If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing.

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive
under certain conditions.

G Always stop the engine and refuel

outdoors or in a well ventilated area.

G Do not smoke or allow open flames

or sparks in or near the area where
refueling is performed or where
gasoline is stored.

G Donot overfill the tank. Donot fill the

tank neck.

G If you get gasoline in your eyes or if

you swallow gasoline, seek medical
attention immediately.

G If you spill gasoline on your skin or

clothing, immediately wash it off with
soapand water and change clothing.

G Never start the engine or let it run in

an enclosed area. Engine exhaust
fumes are poisonous and can result
loss of consciousness or death in a
short time.

G Never drain the float bowl when the

engine is hot. Severe burns may
result.

FUEL LINES

Fuel Lines

Pulse Line

Fuel Pump

Ill.1

1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.

2. Besurefuel linesare routed properly andsecured
with cable ties. CAUTION: Make sure lines are
not kinked or pinched.

3. Replace all fuel lines every two years.

Fuel Filter

2.17

MAINTENANCE

VENT LINES

1. Check fuel tank, oil tank, carburetor, battery and
transmission vent lines for signs of wear,
deterioration, damage or leakage. Replace every
two years.

2. Be sure vent lines are routed properly and
secured with cable ties. CAUTION: Make sure
lines are not kinked or pinched.

FUEL FILTER

The fuel filter should be replaced in accordance with
the Periodic Maintenance Chart.

1. Shut off fuel supply at fuel valve.

2. Remove line clamps at both ends of the filter.

3. Remove fuel lines from filter.

4. Install new filter and clamps onto fuel lines with
arrow pointed in direction of fuel flow.

Fuel Filter Located Close To Carburetor

1. Turn fuel valve to the off position.

2. Place a clean container beneath the bowl drain
spigot or bowl drain hose.

Fuel Valve Location

RES

OFF

Arrow Indicates Direction of Flow

To Carburetor

5. Install clamps on fuel line.

6. Turn fuel valve ON.

7. Start engine and inspect for leaks.

CARBURETOR DRAINING

The carburetor float bowl should be drained
periodically to remove moisture or sediment from the
bowl, or before extended periods of storage.

Drain tube

attached

here

ON

Fuel Valve

3. Turn drain screw out two turns and allow fuel in
the float bowl and fuel line to drain completely.

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turnfuelvalveto“ON”.

7. Start machine and check for leaks.

NOTE: If there is a tube attached, it must be
reattached as this will effect engine performance.

Drain Screw

NOTE: Thebowl drain screwis located onthebottom
left side of the float bowl.

2.18

MAINTENANCE

COMPRESSION TEST

NOTE: This Polaris 4-Strokeengine is equipped with

an automatic decompressor. Compression readings
will vary in proportion to cranking speed during the
test. Average compression (measured) is about

70--90 psi

Smooth idle generally indicates good compression.
Low engine compression is rarely a factor in running
condition problems above idle speed. Abnormally
high compression can be caused by a decompressor
malfunction, or worn or damaged exhaust cam lobes.
Inspect camshaft and automatic decompression
mechanism if compression is abnormally high.

A cylinder leakage test isthe best indication ofengine
condition on models with automatic decompression.
Follow tester manufacturer’s instructions to perform
a cylinder leakage test. (Never use high pressure
leakage tester as crankshaft seals may dislodge and
leak).

Cylinder Compression w/ decompressor

Cylinder Leakage

during a compression test.

Standard 70--90 PSI

BATTERY MAINTENANCE

WARNING

Battery electrolyte ispoisonous. Itcontains
sulfuric acid. Serious burnscanresultfrom
contact with skin, eyes or clothing. Anti­dote:

External: Flush with water.
Internal: Drink large quantities of water or

milk. Follow with milk of magnesia, beaten
egg, or vegetable oil. Call physician im­mediately.

Eyes: Flush with water for 15 minutes and
get prompt medical attention.

Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc. away. Venti­late when charging or using in an enclosed
space. Always shield eyes when working
nearbatteries. KEEPOUTOF REACH OF
CHILDREN.

Service Limit: 10 %

(Inspect for cause if leakage exceeds 10%)

ENGINE MOUNTS

Inspect rubber engine mounts for cracks or damage.

ENGINE FASTENER TORQUE

Check engine fasteners and ensure they are tight.

SEALED LOW MAINTENANCE

BATTER

NOTE: All Low Maintenance batteries are fully
charged and tested at the factory before
installation. Expected shelf life varies on storage
conditions. As a general rule before placing the
battery into service, check the battery condition
and charge accordingly .

Battery Check:

1. Check the date label on the side of the battery to
calculate when to check voltage. The battery
should be checked every 3 months.

2. Check the voltagewith a voltmeter or multimeter.

A fully charged battery should be 12.8 V
higher

3. Ifthe voltage is below12.8V,the battery will need
to be recharged.

Y

or

.

2.19

MAINTENANCE

SEALED LOW MAINTENANCE

New Batteries: Batteries must be fully charged
before use or battery life can be reduced by
10-30% of full potential. Charge battery for 3--5
hours using a variable rate charger. Do not use
thealternator tochargeanew battery. A high rate
battery charger can cause battery damage.

Low Maintenance batteries are permanently
sealed at the time of manufacture. The use of
lead--calcium and AGM technology instead of
lead--antimony allows the battery acid to be fully
absorbed. For this reason, a Low Maintenance
battery case is dark and the cell caps are not
removable, since there is no need to check
electrolyte level.

NEVER
Maintena nc e batte r y. Doing so will damage the
case and shorten the life of the battery. Refer to the
Battery Activation and Maintenance Video (PN

9917987) for proper instruction on servicing Low
Maintenance batteries.

NEVERattempt to add electrolyteor waterto a Low
Maintena nc e batte r y. Doing so will damage the
case and shorten the life of the battery. Refer to the
Battery Maintenance Video (PN 9917987) for proper
instruction on servicing Low Maintenance
batteries.

attempt to add electrolyte or water to a Low

BATTERY

If battery voltage is 12.8 V or less, the battery may
need recharging. When using an automatic charger,
refer to the charger manufacturer’s instructions for
recharging. When using a constant current charger,
use the following guidelines for recharging.

NOTE: Always verify battery condition beforeand 1-2
hours after the end of charging.

WARNING: An overheated battery could explode,
causing severe injury or death. Always watch
charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool
before resuming charging.

CHARGING

Battery Charging Reference Table

State of
Charge

100% 12.8--13 V None,

75--100% 12.5--12.8 V May need

50--75% 12.0--12.5 V Needs

25--50% 11.5--12.0 V Needs

0--25% 11.5 V or

Voltage Action Charge

Time

note below)

None Re-

less

check volt­age at 3
mos. after
manufac­ture date

slight
charge

Charge

Charge

Needs
Charge

quired

3--6 hours

5--11 hours

At least 13
hours,
verify state
of charge

At least 20
hours

(*See

To service a Low Maintenance battery:

1. Remove battery from the vehicle

2. Test battery with a voltage meter or load tester to
determine battery condition. This will determine
thelengthof time requiredto chargethebatteryto
full capacity. Refer to capacity table.

3. Charge battery using a variable rate charger.

2.20