Pantone 425 C
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
ALWAYS USE |
NEVER USE |
NEVER CARRY |
NEVER USE |
AN APPROVED |
ON PUBLIC |
PASSENGERS |
WITH DRUGS |
HELMET AND |
ROADS |
|
OR ALCOHOL |
PROTECTIVE |
|
|
|
GEAR |
|
|
|
NEVER operate:
S without proper training or instruction.
S at speeds too fast for your skills or the conditions.
Son public roads - a collision can occur with another vehicle.
Swith a passenger - passengers affect balance and steering and increase risk of losing control.
ALWAYS:
Suse proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns.
Savoid paved surfaces - pavement may seriously affect handling and control.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
For your nearest Polaris dealer, visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
U.S.A.
Part No. 9922077 Rev 02
Printed in U.S.A.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.
•Snowmobiles
•All-terrain vehicles (ATVs)
•Quadricycles
•RANGER utility vehicles
•Victory motorcycles
Always follow the instructions and recommendations in this manual. The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician. 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.
1
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
Printed in Taiwan
2009 Scrambler 500 2X4 International Owner’s Manual P/N 9922077
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Emission Control Systems . . . . . . . . . . . . . . . 49
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 102
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 104
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 105
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 111
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3
INTRODUCTION
The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
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.
4
INTRODUCTION
WARNING
Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.
•Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating the vehicle.
•Never operate this vehicle without proper instruction. Take a training course.
•This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
•This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited.
5
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. The ignition switch must be replaced if all keys are lost.
####
VIN
Key Number
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
(right front side of engine crankcase)
Key Number: ___________________________________________________________
6
SAFETY
Safety Training
When you purchased your new Polaris vehicle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis.
If you purchased your vehicle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.
Equipment Modifications
The warranty on your Polaris vehicle may be terminated if any equipment 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.
7
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
|
Eye Protection |
Helmet |
Long |
|
Sleeves |
|
Gloves |
Long Pants
Boots
Helmet
Always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.
E4
051039
0006.31
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SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.
9
SAFETY
Operator Safety
WARNING
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.
Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating this vehicle.
Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com.
Never permit others to operate this vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.
Never allow anyone under 16 years of age to operate this vehicle.
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SAFETY
Operator Safety
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
•Always exercise extreme caution whenever handling gasoline.
•Always refuel with the engine stopped, and outdoors or in a well ventilated area.
•Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
•Do not overfill the tank. Do not fill the tank neck.
•If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.
•Turn the fuel valve off whenever the vehicle is stored or parked.
Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas.
Always inspect your vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 33.
Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.
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SAFETY
Operator Safety
Never consume alcohol or drugs before or while operating this vehicle.
Keep both hands on the handlebars. Keep both feet on the footrests.
Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.
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SAFETY
Operator Safety
Never carry a passenger on the rear rack. Ejection from the vehicle or contact with moving components can result in serious injury or death.
Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control, accident and/or injury. Avoid sudden turns or swift movement of the handlebars.
Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.
13
SAFETY
Operator Safety
Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle
overturn. See page 37.
Never attempt jumps or other stunts.
Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 43.
14
SAFETY
Operator Safety
Always follow the procedures outlined in this manual for driving on hills. See page 39. Never operate on hills too steep for this vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills
steeper than 25°.
Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 41.
Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See
page 42.
Always follow the procedures outlined in this manual for crossing the side of a hill. See page 40. Never attempt to turn this vehicle around on any hill until you've mastered (on level ground)
the turning technique outlined in this manual.
15
SAFETY
Operator Safety
Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.
Always travel slowly when operating on unfamiliar terrain. Use extra caution.
Always follow the procedures outlined in this manual for driving in reverse. See page 45.
Use caution when operating on rough, slippery or loose terrain.
Always follow the procedures outlined in this manual for operating over obstacles. See page 44.
Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 38.
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SAFETY
Operator Safety
Never operate this vehicle on a frozen body of water.
Never modify a Quadricycle through improper installation or use of accessories.
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.
If this vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.
Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.
For more information about Quadricycle safety, contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com.
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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, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label.
General Warning
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL NEVER operate:
•without proper training or instruction
•at speeds too fast for your skills or the conditions
•on public roads - a collision can occur with another vehicle
•with a passenger - passengers affect balance and steering and increase risk of losing control
ALWAYS:
•use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns
•avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175376
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SAFETY
Safety Labels and Locations
Discretionary
Warning
+
+
General
Warning
Discretionary Warning
WARNING
•Never operate this ATV on HILLS steeper than 25 degrees 
25°. To prevent 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
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SAFETY
Safety Labels and Locations
Age 16
Warning
“No Passenger”
Warning
++
++
Tire Pressure/Load
Warning
Clutch Cover
Warning
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
7175378
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.
• Cold tire pressure:
Front: 4.0 psi (27.6 kPa) Rear: 3.0 psi (20.7 kPa)
• Maximum weight capacity: 275 lbs. (125 kg)
7175443
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SAFETY
Safety Labels and Locations
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
NEVER operate this ATV if you are under age 16.
7175374
Clutch Cover Warning
WARNING
•Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.
•Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.
NO STEP
7172563
Reverse Override 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
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FEATURES AND CONTROLS
Switches
Headlight Switch
Engine
Stop Switch
Override
Switch
Main Key Switch
Override Switch
This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and press the override switch.
WARNING! Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override switch.
The override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on.
Engine Stop Switch
Move the stop switch either left or right to |
|
the OFF position to stop the engine |
|
quickly. The engine will not start or run |
|
when the switch is off. |
OFF RUN OFF |
Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.
Main Key Switch
Use the main key switch to start the engine. See page 34 for starting procedures.
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FEATURES AND CONTROLS
Switches
Headlight Switch
Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights.
Indicator Lights
With the engine running, verify the function of all indicator lights before each use of the vehicle.
Tip: The taillight is on whenever the main switch (key) is on. Turn the key off to prevent battery drain.
Reverse Indicator
High Temperature Warning |
Neutral Indicator |
(displays if engine overheats) |
|
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FEATURES AND CONTROLS
Throttle Lever
Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement.
Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.
Do not start or operate a vehicle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.
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FEATURES AND CONTROLS
Brake Lever
Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes
are hydraulically activated disc type brakes that are activated
by only one lever.
Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any
sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.
Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.
Inspect and maintain the brake fluid level as outlined in this manual. See page 63.
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FEATURES AND CONTROLS
Parking Brake
1. Place the transmission in
gear.
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.
Operating the vehicle while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.
The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the vehicle if leaving it parked on a hill. Another option is to park the vehicle in a sidehill position. Never depend on the parking brake alone if the vehicle is parked on a hill. Always block the wheels to prevent rolling.
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FEATURES AND CONTROLS
Auxiliary Foot Brake
Aggressively applying the auxiliary rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.
Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control, which may result in serious injury or death.
The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.
The auxiliary foot brake is located on the inside of the right footrest. Operate this brake with your right foot.
If the rear wheels slide while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.
Auxiliary
Foot Brake
27
FEATURES AND CONTROLS
Choke
The choke assists in starting a cold engine. Refer to the engine starting procedure on page 34 for correct choke and throttle settings during starting.
Fuel Tank Cap
Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface.
Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel.
Fuel
Tank
Cap
Fuel
Valve
Fuel Valve
The fuel valve is located on the left side of the vehicle, below the fender.
ON: For normal operation.
OFF: For vehicle storage |
OFF |
ON |
RES |
and when transporting. |
|
|
|
RES: Turn the valve to the reserve setting if the main fuel supply is exhausted. Refuel as soon as possible. Return the valve to the ON position after refueling.
Reserve fuel range is about 7-10 miles (11-16 km).
Fuel Filter
The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.
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