Polaris Scrambler 500 4x4 User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

Copyright 2005 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 U.S.A.

2006 Scrambler 500 4X4 Owner’s Manual P/N 9920153

TABLE OF CONTENTS

VEHICLE IDENTIFICATION NUMBERS 5.......

SAFETY 6...................................

FEATURES AND CONTROLS 31...............

OPERAT ION 43..............................

EMISSION CONTROL SYSTEMS 61............

MAINTENANCE AND LUBRICATION 62........

SPECIFICATIONS 104........................

POLARIS PRODUCTS 107....................

TROUBLESHOOTING 108.....................

WARRANTY 112.............................

MAINTENANCE LOG 116.....................

INDEX 118...................................

VEHICLE IDENTIFICATION NUMBERS

Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

31XX

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number (right front side of engine crankcase):

Key Number (2):

SAFETY

Operator Safety

WARNING

Failure to follow the warnings contained in this manual can result in serious injury or death.

A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings before operating a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Safety Training

When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.

We strongly advise you to strictly follow the recommended maintenance program outlined in your owner’s manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual.

S Read this manual and all labels carefully, and follow the operating

procedures described.

S Never operate an ATV without proper instruction. Take a training

course. Beginners should receive training from a certified instructor.

Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

S Never allow anyone under 16 years of age to operate this ATV. S Never permit a guest to operate the ATV unless the guest has read

this manual and all product labels and has completed a certified safety training course.

S Always avoid operating an ATV on paved surfaces, including side-

walks, driveways, parking lots, and streets.

S Never operate an ATV on a public street, road or highway, including

a dirt or gravel road.

S Never operate an ATV without wearing an approved helmet that fits

properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating an ATV. S Never operate at excessive speeds. Travel at speeds appropriate for

the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV before each use to make sure it’s in safe

operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner’s manual.

S Always keep both hands on the handlebars and both feet on the foot-

rests of the ATV during operation.

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manu-

al. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.

SAFETY

Operator Safety

S Always have the ATV inspected by an authorized Polaris dealer if

it’s been involved in an accident.

S Never operate on hills too steep for the ATV or for your abilities.

Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. Check the ter-

rain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.

S Always follow proper procedures for crossing the side of a hill.

Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you’ve mastered (on level ground) the turning t echnique outlined in this manual. Avoid crossing the side of a steep hill when possible.

S Always use proper procedures if you stall or roll backwards while

climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual.

S Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

S Always be careful of skidding or sliding. On slippery surfaces like

ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

S Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

SAFETY

Operator Safety

S Wet brakes may have reduced stopping ability. Test your brakes after

leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.

S Always check for obstacles or people behind t he ATV before operat-

ing in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles.

S Always use the size and type of tires specified for your ATV, and

always maintain proper tire pressure.

S Never modify an ATV through improper installation or use of acces-

sories.

S Never exceed the stated load capacity for your ATV. 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.

S Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or call Polaris at 1-800-342-3764.

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited

to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN The risk of an accident is greatly increased if the operator does

not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE Beginning and inexperienced operators should complete the

certified training course offered by Polaris. Operators should regularly practice the skills learned in the course and the operating techniques described in the owner’s manual.

For more information about the training course, contact an authorized ATV dealer or call Polaris at 1-800-342-3764.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN Severe injury and/or death could occur if a child under the

minimum age recommendation operates an ATV. Even though a child may be within the recommended age group

for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury.

HOW TO AVOID THE No one under the age of 16 should operate a Polaris ATV.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Carrying a passenger on an

ATV. WHAT CAN Carrying a passenger

greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger.

HOW TO AVOID THE 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.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating an ATV

on paved surfaces, including sidewalks, paths, parking lots, and driveways.

WHAT CAN ATV tires are designed for

off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.

HOW TO AVOID THE Avoid operating the ATV on pavement. If it’s unavoidable, travel

slowly and avoid sudden turns or stops.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV on

public streets, roads or highways.

WHAT CAN The ATV could collide

with another vehicle. HOW TO AVOID THE Never operate the ATV on any

public street, road or highway, including dirt and gravel roads. In many states it’s illegal to operate ATVs on public streets, roads and highways.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating this ATV without

wearing an approved helmet, eye protection and protective clothing.

WHAT CAN Operating an ATV without

an approved helmet increases the risk of a severe head injury or death in the event of an accident.

Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident.

HOW TO AVOID THE Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves,

boots, long-sleeved shirt or jacket, and long pants.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV after consuming

alcohol or drugs. WHAT CAN Consumption of alcohol and/or drugs

could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.

HOW TO AVOID THE Never consume alcohol or drugs before or while operating an

ATV.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN Excessive speed increases the operator’s chance of losing

control of the ATV, which can result in an accident. HOW TO AVOID THE Always operate the ATV at a speed that’s proper for the terrain,

visibility and operating conditions, and your experience.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps

and other stunts. WHAT CAN Attempting stunts increases

the chance of an accident, including an overturn.

HOW TO AVOID HAZARD

Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

HAPPEN

THE

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the A TV. WHAT CAN Poor maintenance increases the possibility of an accident or

equipment damage. HOW TO AVOID THE Always inspect your ATV before each use to make sure it’s in

safe operating condition. Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests

during operation. WHAT CAN Removing even one hand or foot can reduce ability to control the

vehicle or could cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footrest, it could

come into contact with the rear wheels and lead to accident or injury.

HOW TO AVOID THE Always keep both hands on the handlebars and both feet on the

footrests of the ATV during operation.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Failure to use extra

caution when operating the ATV on unfamiliar terrain.

WHAT CAN Unfamiliar terrain may

contain hidden rocks, bumps, or holes that could cause loss of control or overturn.

HOW TO AVOID THE Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra

caution when operating on excessively rough, slippery or loose terrain.

WHAT CAN Operating on excessively

rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.

HOW TO AVOID THE Do not operate on excessively rough, slippery or loose terrain

until you’ve learned and practiced the skills necessary to control the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN Improper turns could cause loss of control and lead to a collision

or overturn. HOW TO AVOID THE Always follow proper procedures for turning as described in the

owner’s manual. Practice turning at slow speeds before attempting to turn at faster

speeds. Never turn at excessive speed.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN The vehicle may overturn. HOW TO AVOID THE Never operate on hills too steep for the A TV or for your abilities.

Never operate the ATV on hills steeper than 25_. Practice on smaller hills before attempting large hills.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN Improper hill climbing could

cause loss of control or overturn.

HOW TO AVOID HAZARD

Always follow proper procedures for climbing hills as described in the owner’s manual.

Always check the terrain carefully before ascending any hill.

Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a

sharp drop, or another vehicle or person could be on the other side of the hill.

HAPPEN

THE

Operator Safety

WARNING

POTENTIAL HAZARD Traveling downhill

improperly. WHAT CAN Improperly descending a hill

could cause loss of control or overturn.

HOW TO AVOID HAZARD

Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill. See page 55.

Always check the terrain carefully before descending a hill. Shift your weight backward. Never travel down a hill at high speed. Avoid traveling down a hill at an angle, which would cause the

vehicle to lean sharply to one side. Travel straight down the hill when possible.

HAPPEN

THE

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly crossing hills and

turning on hills. WHAT CAN Improperly crossing or

turning as hills could cause loss of control or overturn.

HOW TO AVOID HAZARD

Neverattempttoturnthe ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 56. Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill. When crossing the side of a Always follow proper procedures as described in the owner’s

manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

HAPPEN

THE

hill:

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards

or improperly dismounting while climbing a hill.

WHAT CAN The vehicle could overturn. HOW TO AVOID

HAZARD Maintain steady speed

when climbing a hill. If all forward speed is Keep your weight uphill. Apply the single lever brake gradually. When fully stopped, apply the auxiliary rear brake as well, then

lock the parking brake. If the ATV begins rolling Keep weight uphill. Never apply engine power. Never apply the auxiliary rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply the auxiliary rear brake as well, and

then lock the parking brake. Dismount on uphill side, or to either side if ATV is pointed straight

uphill. Turn the ATV around and remount, following the procedure

described in the owner’s manual. See page 56.

HAPPEN

THE

lost:

backwards:

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Skidding or sliding. WHAT CAN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE On slippery surfaces such as ice, travel slowly and use extra

caution to reduce the chance of skidding or sliding out of control.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN The ATV could collide with an obstacle or person, resulting in

severe injury. HOW TO AVOID THE Before shifting into reverse gear, always check for obstacles or

people behind the ATV. When it’s safe to proceed, back slowly.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN Tires may float, causing loss of traction and loss of control, which

could lead to an accident or overturn. HOW TO AVOID THE Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable to enter water that exceeds the recommended maximum depth (see page 57), travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or

uneven tire pressure. WHAT CAN Use of improper tires, or operation of the ATV with improper or

uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE Always use the size and type of tires specified for the ATV. Always maintain proper tire pressure as specified.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV with improper modifications. WHAT CAN Improper installation of accessories or modification of the ATV

may cause changes in handling which could lead to an accident. HOW TO AVOID THE Never modify the ATV through improper installation or use of

accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident. HOW TO AVOID THE Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a

greater distance for braking. Always follow the instructions in the owner’s manual for carrying

cargo or pulling a trailer. See page 48.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN Severe injury or death can result if the ATV and/or the operator

fall through the ice. HOW TO AVOID THE Never operate the ATV on a frozen body of water.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

WARNING

Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control, which could result in severe injury or death.

CAUTION

Always keep combustible materials away from the exhaust system. Exposure to the hot components could result in a fire.

SAFETY

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well

ventilated area.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck. S If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.

S Never start the engine or let it run in an enclosed area.

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.

S Turn the fuel valve off whenever the ATV is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV.

If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

WARNING

DNever operate this vehicle on HILLS steeper than 25 degrees

To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually.

DREVERSE operation can be dangerous, even at low speeds. Steering be-

comes difficult. To prevent flipover, avoid sudden braking or sharp turns.

DUse OVERRIDE for reverse speed limiter with caution. To prevent loss

of control, never activate override button with open throttle.

DPARKING BRAKE may relax when used for more than 5 minutes. When

parking on grades, leave shift in forward.

WARNING

Pushing reverse override button may cause sudden increases in power and traction if too much throttle i s applied. Loss of control or forward flipover may result, especially in AWD. See Owner’s Manual.

7172564

25°

7172665

WARNING

S Moving parts hazard under belt-clutch guar d. To

prevent s erious injury, do not operate vehicle with guard r emoved.

S 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

SAFETY

Safety Decals and Locations

WARNING

Improper AT V use can result in SEVERE INJURY or DEAT H

ALWAYS USE

AN APPROVED

HELMET AND PROTECTIVE

GEAR

NEVER operate:

ALW AYS:

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

7172560

WARNING

7172566

7172667

Safety Decals and Locations

SAFETY

WARNING

Do not push switch to engage AWD if the rear wheels are spinning. This may

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.

Chain Freeplay Is Important. Adjust Freeplay to 3/16″ -3/8″ DO NOT Overtension. See Owner’s Manual.

Torque Nut on Ec centric Bolts : To 30 Ft. Lbs. (For models without a hitch). To 40 Ft. Lbs. (For models with ahitch).

MANUFACTURED BY: POLARIS IND. INC.

DATE:

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDEDFOR USE ON PUBLIC ROADS.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.

7172559

7078572

cause severe drive shaft and clutch damage. See your Owner’s Manual.

ALL WHEEL

DRIVE

SWITCH

7079780

Canadian Certification Decal

7171492

Under Seat

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury.

1. Helmet

Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.1), or the Snell Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings z2.1 or VESC 8).

3. Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

4. Boots

The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots.

5. Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

FEATURES AND CONTROLS

Electrical Switches

WARNING

Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open.

Override Switch (1) (Reverse Speed Limiter) This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch.

NOTE: The override switch also allows activation

of AWD in reverse, if the AWD switch is on.

Main Switch (2) - To start the engine, slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position. Release the key when the engine starts.

RUN OFFOFF

NOTE: Turn off the main switch to end all electrical power to the

vehicle, including the lights.

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

Engine Stop Switch (3) - The engine will not start or run when the switch is in its OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. To stop the engine, slide the stop switch either right or left to the OFF position.

NOTE: Turning off the engine stop switch will shut off all electrical

power to the vehicle, including the lights.

FEATURES AND CONTROLS

Light Switches

WARNING

Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death.

Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

The light switch is located on the left handlebar (1). It’ s used to turn the lights on and off and to switch the lights from high beam to low beam.

NOTE: The lights won’t work unless

the key is in the ON position and the shut-off switch is in the RUN position.

Indicator Lights

With the engine running, verify the function of all indicator lights each time the ATV is used.

NOTE: The taillight is on whenever the main switch (key) is on. Turn

the key off to prevent battery drain.

1. Transmission Neutral Indicator

2. Transmission Reverse Indicator

3. HighTempWarning(displays if engine overheats)

FEATURES AND CONTROLS

Throttle Lever

WARNING

Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death.

Always contact your dealer for service repairs if throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.

Always check the lever for free movement and return before starting the engine. Also check occasionally during operation.

Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded. Engine speed returns to idle when the lever is released.

This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

WARNING

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

FEATURES AND CONTROLS

Brake Lever

WARNING

Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever.

The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever.

Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

FEATURES AND CONTROLS

Brakes

Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the left handlebar.

The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This “eye” will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear.

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

NOTE: When checking the fluid level, the A TV must be on level

ground with the handlebars straight. If the fluid level is low add DOT 3 brake fluid only. DO NOT OVERFILL. See page 107 for the part numbers of Polaris products.

WARNING

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

FEATURES AND CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating.

Setting the Parking Brake

1. Squeeze and release the brake lever two or three times, then squeeze and hold.

2. Push the park brake lock (1) forward to engage the brake. Release the brake lever.

3. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.

Important Safeguards

S The parking brake may relax if left on for a l ong period of time. Al-

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the ATV if leaving

it parked on a hill. Another option is to park the ATV in a sidehill position.

S Never depend on the parking brake alone if the ATV is parked on a

hill. Always block the wheels to prevent rolling.

FEATURES AND CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the rear brake when backing downhill may cause rear tipover, which could result in serious injury or death.

Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

The auxiliary foot brake (1), is located on the inside of the right floorboard and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if t he main system becomes inoperative.

If the rear wheels slide while using t he auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.

Check the brake fluid level frequently for t he auxiliary brake system. The reservoir is located under the seat or near the foot brake. Maintain the fluid level between the maximum and minimum marks.

FEATURES AND CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 45 for correct choke and throttle settings during starting.

Fuel Valve

The fuel valve (1) is located on the left side of the vehicle, below the fender. It has three positions:

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if m ain supply is exhausted.

NOTE: There’s about a 7 to 10 mile

(11.2 to 16 km) range on reserve gas. Always refill the gas tank as soon as possible after using the reserve supply.

Always return the valve to the ON position after refueling.

Fuel T ank

The fuel tank filler cap (2) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Refer to the specifications section at the rear of this manual for tank capacity.

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100 hours of operation, or annually. Do not attempt to clean the fuel filter.

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1) is located on the right side of the vehicle.

F: Forward

N: Neutral

R: Reverse

CAUTION

Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.

Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake.

FEATURES AND CONTROLS

Recoil Starter

If the battery has been drained or damaged and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.

Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting. The decompressor senses when the engine is spinning fast enough to start and restores compression when running.

1. Position the vehicle on a level surface and l ock the parking brake (see page 36).

2. Shift the transmission into neutral.

3. Make sure the engine stop switch is set to RUN and the main key switch is in the ON position.

NOTE: If the engine is cold, use the choke as outlined on page 45.

4. Grasp the recoil starter rope handle (2) firmly and pull slowly so you can feel the engine strokes.

NOTE: Every other stroke will be a “compression stroke” and will

make the rope harder to pull. When a compression stroke is found, continue pulling the rope just until the engine rolls past the stroke, then stop pulling immediately.

5. Allow the recoil rope to rewind into the recoil assembly, then pull the rope abruptly and forcefully to start the engine.

6. Repeat steps 4-5 if necessary.

CAUTION

Extending the recoil starter rope until it stops can cause damage to the recoil assembly. Do not extend the starter rope so far that it stops.

If the starter rope handle is not seated properly, water may enter the recoil housing and damage components. Make sure the handle is fully seated on the recoil housing, especially when traveling in wet areas.

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

Polaris 4-wheel drive ATVs are equipped with a unique, Polaris exclusive, AWD system that’s activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV is in AWD and the A WD indicator light (2) will be on.

When in AWD, the front hubs will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front hubs will automatically disengage.

NOTE: The override switch allows activation of AWD in reverse if the

AWD switch is on. See page 31.

There is no limit to the length of time the vehicle may remain in AWD.

Engaging Wheel Hubs

The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is turned off while the front hubs are moving, the hubs will not disengage until the rear wheels regain traction.

Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning may cause severe drive shaft and hub damage. Always switch to AWD while the rear wheels have traction or are at rest.

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

Disengaging Wheel Hubs

Although the hubs normally disengage when operating in reverse, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, it’s likely that one front hub is engaged . If both hubs are engaged, steering effort increases but remains balanced from left to right, and vehicle speed is somewhat restricted.

Disengage the hubs by stopping, shifting to reverse, and backing for a short distance. Then proceed in forward again.

NOTE: If the hubs remain engaged after following this procedure,

To continue using AWD in reverse, activate the override switch and the AWD switch. See page 31.

return the ATV to your dealer for service.

WARNING

Operating with only one front hub engaged could result in loss of control, accident, and severe injury or death. When hub engagement symptoms are present, use the disengaging procedure before proceeding.

OPERATION

Break-In Period

The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

CAUTION

Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel t ank with gasoline (see page 38).

2. Check the oil level on the dipstick (see page

68). Add the recommended oil as needed to maintain the oil level in the normal operating range (1).

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

4. Vary throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 44.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 25 hours or one month, whichever comes first.

ADD 8 OZ. NORMAL FULL

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.

Pre-Ride Checklist

Item Remarks See

Page

Brake system / lever travel Ensure proper operation 34, 76

Brake fluid Ensure proper level 35

Auxiliary brake Ensure proper operation 77

Front suspension Inspect, lubricate if necessary 66

Rear suspension Inspect, lubricate if necessary 66

Steering Ensure free operation --

Tires Inspect condition and pressure 83

Wheels / fasteners Inspect, ensure fastener tightness 82

Frame nuts, bolts, fasteners Inspect, ensure tightness --

Fuel and oil Ensure proper levels 68

Coolant level (if applicable) Ensure proper level 86

Coolant hoses (if applicable) Inspect for leaks --

Throttle Ensure proper operation 33, 78

Indicator lights / switches Ensure operation 31, 32

Engine stop switch Ensure proper operation 31

Drive chain Check condition / slack, lubricate as

needed

Air filter, pre-filter Inspect, clean 90

Air box sediment tube Drain deposits whenever visible --

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light / tail lamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Riding gear Wear helmet, goggles, protective

clothing

74, 84

OPERATION

Starting the Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

Starting a Cold Engine

CAUTION

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

1. Place the transmission in neutral and lock the parking brake. Make sure the fuel tank valve is on.

2. Sit on the vehicle and pull the choke knob (1) out until it stops.

NOTE: If the knob doesn’t stay

where positioned, increase the tension by rotating the tension adjusting nut (2) clockwise.

The variable choke is fully on when the knob is pulled completely out. The choke is off when the knob is pushed completely in. The choke can be adjusted gradually, depending on how much choke is needed for starting. Be sure the choke is off during operation, as excess fuel washing into the engine oil will increase wear on engine components.

3. Move the engine stop switch to RUN.

NOTE: Do not press the throttle while starting the engine.

OPERATION

Starting the Engine

Starting a Cold Engine

4. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. If the engine does not start, release the key and wait five seconds. Then activate the starter for another five seconds. Repeat this procedure until the engine starts.

5. If the engine slows or stops, position the choke knob half way in to allow proper engine warm up.

6. Vary the engine RPM slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke all the way in.

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Excessive use of the choke can cause the spark plug to become wet fouled.

1. Position the vehicle on a level surface with the transmission in neutral.

2. Lock the parking brake, turn the fuel tank valve to ON, sit on the vehicle, and turn the engine stop switch to RUN.

3. If the engine has cooled to a point where it does not readily start, intermittent use of the choke button (pulled half way out) may be necessary.

4. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in starting.

5. Release the throttle lever immediately after the engine starts. If the engine does not start and all conditions are favorable, change the sparkplugandtryagain.

OPERATION

Driving Safely

Driving Procedures

1. Sit upright with both feet on the footrests and both hands on the handlebars.

2. Start the engine and allow it to warm up, then shift the transmission into gear.

3. Check your surroundings and determine your path of travel.

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening.

6. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

OPERATION

Driving Safely

Hauling Cargo

2/3

1/3

Accessory racks and hitches are available from your Polaris dealer. Always read and understand the load distribution warnings on all warning labels, and never exceed the specified weight capacities for the vehicle.

Maximum Towing Capacities

Refer to the specifications at the rear of this manual for towing capacities. When towing, reduce the rear rack cargo load capacity by the amount of trailer tongue weight.

Never tow any trailer on a grade steeper than 15°.

OPERATION

Driving Safely

Hauling Cargo

WARNING

Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo:

S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR

BRAKING WHEN HAULING CARGO.

S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front

rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on one rack only increases the possibility of vehicle overturn.

S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS

POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

S ALL LOADS MUST BE SECURED BEFORE OPERATING.

Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

LOADS. When handling off-centered loads that cannot be centered, securely fasten load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

S 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.

S EXTREME CAUTION MUST BE USED when operating with

loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry-

ing loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED

SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

OPERATION

Driving Safely

Making Turns

Your Polaris ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire m ust slip traction slightly.

To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to

turn at faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds.

OPERATION

Driving Safely

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids.

3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

4. Driving with AWD engaged can assist in controlling the vehicle in slippery areas.

CAUTION

Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning.

WARNING

Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death.

Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.

OPERATION

Driving Safely

Sidehilling

WARNING

Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual.

Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle directions.

NOTE: If the vehicle begins to tip, quickly turn the front wheel

downhill, if possible, or dismount on the uphill side immediately!

OPERATION

Driving Safely

Driving Uphill

25_

Maximum

WARNING

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

5. Proceed at a steady rate of speed and throttle opening.

6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.

If all forward speed is lost:

Keep your weight uphill. Apply the single lever brake, gradually. When fully stopped, apply the

auxiliary brake as well, then lock the park brake.

If the ATV begins rolling backwards:

Keep your weight uphill. Never apply engine power. Never apply the auxiliary rear brake while rolling backwards.

Apply t he single-lever brake, gradually. When fully stopped, apply the auxiliary rear brake as well, and then lock the parking brake.

Dismount on uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described on page 56.

OPERATION

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

2. Transfer your weight to the rear of the vehicle.

3. Slow down.

4. Apply the brakes slightly to aid in slowing, using the single brake lever.

NOTE: Familiarize yourself with operation of the auxiliary rear brake

pedal for additional braking in the event of normal service brake loss.

WARNING

Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.

OPERATION

Driving Safely

Turning Around on a Hill

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

8’ (2.4 m)

1. Stop and lock the parking brake while keeping body weight uphill.

2. Leave the transmission in forward and shut off the engine.

3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.

4. Staying uphill of the vehicle, turn the handlebars full left.

5. While holding the brake lever, release the parking brake lock and slowly allow the vehicle to roll around to your right until it’s pointing across the hill or slightly downward.

6. Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill.

7. Restart the engine with the t ransmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed with the brake, until the vehicle is on more level ground.

OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:

1. Determine water depths and current before crossing.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.

After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 62. The following areas need special attention: engine oil, transmission oil, front and rear gearcases (if equipped), and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart.

If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing

water. If you cannot avoid water that exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

If your vehicle becomes immersed, and it’s impossible to take it to a dealer before starting it, follow the steps described on page 92. Have the vehicle serviced by your dealer at the first opportunity.

OPERATION

Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches.

WARNING

Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.

OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always avoid backing downhill.

2. Back slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

WARNING

Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it’s safe to proceed, back slowly.

Do not use the override switch unless additional power is required for vehicle movement. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: This Polaris ATV is equipped with a reverse speed limiter.

The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

OPERATION

Driving Safely

ParkingonanIncline

Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:

1. Turn the engine off.

1. Place the transmission in gear.

2. Set the parking brake.

3. Always block the rear wheels on the downhill side. See illustration.

4. Shut off the fuel supply.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 8343. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be 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.

The emissions label is located on the recoil cover or stator housing.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with European directives 97/24/EC and 89/336/EEC.

MAINTENANCE AND LUBRICATION

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 116.

NOTE: Service and adjustments are important for proper vehicle

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load operation S Extended idle S 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.

operation. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

MAINTENANCE AND LUBRICATION

onpage4

Periodic Maintenance Chart

Maintenance Chart Key

" Perform these procedures more frequently for vehicles subjected to

severe use.

E Emission-related service (Failure to conduct this maintenance will

not void t he emissions warranty but may affect emissions.)

J Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Steering -- Pre-Ride --

Front suspension -- Pre-Ride --

Rear suspension -- Pre-Ride --

Tires -- Pre-Ride --

Brake fluid level -- Pre-Ride --

Brake lever travel -- Pre-Ride --

Brake system -- Pre-Ride --

Wheels/fasteners -- Pre-Ride --

Frame fasteners -- Pre-Ride --

Engine oil level -- Pre-Ride --

Air filter, pre-filter -- Daily -- Inspect; clean often; replace

Air box sediment

tube

Coolant -- Daily -- Check level daily, change

Headlamp/tail lamp

Air filter,

main element

Recoil housing -- Weekly -- Drain water as needed,

-- Daily -- Drain deposits when visible

-- Daily -- Check operation; apply

-- Weekly -- Inspect; replace as needed

(Km)

Make adjustments as needed. See Pre-Ride Checklist on page 44.

as needed

coolant every 2 years

dielectric grease if replacing

check often if operating in wet conditions

Remarks

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Brake pad wear 10 H Monthly 100 (160) Inspect periodically

" J

Battery 20 H Monthly 200 (320) Check terminals; clean; test

Front gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly

Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly

Engine breather

filter (if equipped)

General

lubrication

Carburetor float bowl

Throttle Cable/

ETC Switch

Choke cable 50 H 6M 500 (800) Inspect; adjust; lubricate;

25 H Monthly 250 (400) Inspect; clean if needed

50 H 3M 500 (800) Lubricate all fittings, pivots,

50 H 6M 500 (800) Drain bowl periodically and

50 H 6M 500 (800) Inspect; adjust; lubricate;

Carburetor air

intake ducts/ flange

Drive belt 50 H 6M 500 (800) Inspect; adjust; replace as

Cooling system 50 H 6M 1000 (1600) Inspect coolant strength

Engine oil change 100 H 6M 1000 (1600) Perform a break-in oil

Oil filter change 100 H 6M 1000 (1600) Replace with oil change

Oil tank vent hose 100 H 12 M 1000 (1600) Inspect routing, condition

Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust

50 H 6M 500 (800) Inspect ducts for proper

(Km)

cables, etc.

prior to storage

replace if necessary

sealing/air leaks

needed

seasonally; pressure test system yearly

change at one month

Remarks

Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,

Radiator

(if applicable)

100 H 12 M 1000 (1600) Inspect; clean external

lines, fuel valve, filter, pump, carburetor; replace lines every two years

surfaces

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Cooling hoses

(if applicable)

Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

100 H 12 M 1000 (1600) Inspect for leaks

100 H 12 M 1000 (1600) Inspect

(Km)

Remarks

Ignition Timing 100 H 12 M 1000 (1600) Inspect

Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

Clutches (drive

and driven)

Front wheel

bearings

Brake fluid 200 H 24 M 2000 (3200) Change every two years

Spark arrestor 300 H 36 M 3000 (4800) Clean out

Idle speed -- Adjust as needed

Toe adjustment -- Inspect periodically; adjust

Headlight aim -- Adjust as needed

100 H 12 M 1000 (1600) Inspect; clean; replace worn

100 H 12 M 1000 (1600) Inspect; replace as needed

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

parts

when parts are replaced

" Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

J Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Items not listed in the chart should be lubricated at the General Lubrication interval.

NOTE: The a-arms and lower control arms are lubricated at the

factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user’s discretion.

Lubrication Chart Key

" More often under severe use, such as wet or dusty conditions

L Polaris Premium All Season Grease or grease conforming to NLG

No. 2, such as Conoco Superlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging

∆ When suspension action becomes stiff, or after washing

Item Lube Method

4-Cycle Engine Premium 4

Brakes DOT 3 fluid only Maintain level between fill lines.

Drive chain(s) O-ring chain lube or

(1) Transmission AGL Synthetic

(2) Front Gearcase ATV Angle Drive Fluid Maintain as recommended on

(3) Front Prop Shaft Yoke FGrease Grease fittings

(4) Swing Arm Bushings

(5) Tie Rod Ends

(6) Front Hubs Premium Hub Lube Remove set screw in hubs. Rotate

(7) Ball Joint

(8) Axle Housing

Synthetic 0W40

SAE 80/90

Gearcase Lube

"LGrease

"L∆Grease

"LGrease

"L Grease

Add to proper level on dipstick.

See page 35.

Lubricate.

Maintain as recommended on page 72.

page 73.

(3 pumps maximum).

Locate fittings on swing arm and grease with grease gun.

Lift boot, clean away dirt and grease, apply fresh grease by hand and reassemble.

wheels to 4 O’clock position. If lubricant is not visible add more. Reinstall set screw.

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

Locate fittings on swing arm and grease with grease gun.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(1)

(5)

(2)

(3)

(7)

(4)

(8)

(6)

4 or 8 o’clock

position- (end view)

MAINTENANCE AND LUBRICATION

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil.

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. Polaris recommends the use of Premium 4 in this engine, but use of any API certified “SH” oil is allowable as long as it’s 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer’s recommendations for ambient temperature operation.

See page 107 for the part numbers of Polaris products.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified “SH” oil, 0W-40. Never substitute or mix oil brands.

Oil Check

1. Position the ATV on a level surface.

2. Start the engine and let it idle for 20-30 seconds. Stop the engine.

3. Remove the dipstick (1), which is located on the left side of the vehicle.

4. Wi pe the dipstick dry with a clean cloth. Reinstall it and screw it completely in.

NOTE: The dipstick must be

screwed completely in to keep the angle and depth of the stick consistent.

5. Remove the dipstick and read the oil level. Maintain the oil level in the normal operating range (2). Do not overfill.

ADD 8 OZ. NORMAL FULL

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Ch ange

CAUTION

Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin.

1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine.

2. Run the engine for two to three minutes, then turn it off.

3. Place a drain pan beneath the oil tank and remove the drain plug (1). Allow the oil to drain completely.

4. Install a new sealing washer (2) on the oil drain plug.

NOTE: The sealing surfaces on the drain plug and the oil tank

should be clean and free of burrs, nicks or scratches.

5. Reinstall the drain plug and torque to 14-17 ft. lbs. (19-23 Nm).

6. Disconnect the lower oil delivery hose and remove the screen fitting (3) from

the oil tank. Clean the fitting.

NOTE: The fitting threads

must be sealed with LOCTITE PST 505 or PTFE seal tape.

7. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark (4) on the tank.

NOTE: Do not over-tighten. Maximum torque for the screen fitting is

25 ft. lbs. (34 Nm).

8. Reattach the oil line.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Ch ange

9. Place shop towels beneath t he oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove.

10. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine.

11. Install the new filter and tighten by hand 1/2 to 3/4 turn after gasket contacts the engine.

12. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug on the lower right side of the crankcase.

NOTE: Thesealingsurfaceson

the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

13. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

14. Remove the dipstick (2) and add two quarts (1.9 l) of the recommended oil. Reinstall the dipstick.

NOTE: If the sump is not drained, add about 1 3/4 quarts initially.

15. Pl ace the gear selector in neutral and set the parking brake.

16. Prime the oil pump using the procedure on page 71.. Then stop the engine and inspect for leaks.

17. Recheck the oil level on t he dipstick and add oil as necessary to bring it to the recommended level on the dipstick.

18. Dispose of used filter and oil properly.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Ch ange Oil Pump Priming

This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.

1. Clamp or pinch off the vent

line (1) approximately 2I from the oil tank (2), between the end of the oil tank vent fitting and the vent line’s pressure relief slit (3).

2. Run the engine for 10-20 seconds.

3. Remove the vent line clamp. If the line is bled properly, you should hear a rush of air, indicating that the line i s properly primed and ready for operation. If you do not hear

air, the line has not bled, and you’ll need to repeat the priming procedure.

MAINTENANCE AND LUBRICATION

Transmission Oil

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level at the bottom of the fill hole threads. We recommend the use of P remium AGL Synthetic Gearcase Lubricant. See page 107 for the part numbers of Polaris products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the propshaft shield from the right side of the vehicle to access the fill plug. Remove the fill plug (1).

3. Check the oil level. Add the recommended lubricant as needed.

4. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

5. Reinstall the propshaft shield.

Oil Change

1. Position the ATV on a level surface.

1. Remove the propshaft shield from the right side of the vehicle to access the fill plug. Remove the fill plug.

2. Remove the transmission drain plug located on the bottom left-hand side and drain the oil into an appropriate container. Discard used oil properly.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add the proper amount of the recommended lubricant. Refer to the specifications section beginning on page 104 for capacities.

5. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

6. Check for leaks.

7. Reinstall the propshaft shield.

MAINTENANCE AND LUBRICATION

Front Gearcase Oil

Oil Check

Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level at the bottom of the fill plug threads. We recommend the use of Polaris ATV Angle Drive F luid. See page 107 for the part numbers of Polaris products.

1. Position the ATV on a level surface.

2. Remove the fill plug (1) and check the oil level.

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

Oil Change

1. Position the ATV on a level surface.

2. Remove the fill plug.

3. Place a drain pan beneath the gearcase, remove the gearcase drain plug, and drain the oil. Discard used oil properly.

4. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

5. Add 4 oz. (120 ml) of the recommended gearcase oil.

6. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

7. Check for leaks.

MAINTENANCE AND LUBRICATION

Drive Chain

Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated.

Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or damaged rollers. Also check for correct slack adjustment. Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm).

Regularly lubricate the drive chain with Polaris Chain Lube, an SAE 80-90 lube or an approved o-ring chain spray lube. See page 107 for the part numbers of Polaris products.

CAUTION

Washing the drive chain with a high pressure washer or gasoline can cause damage to the o-rings, causing premature wear and drive chain failure. Do not use a high pressure washer or gasoline to clean the drive chain.

MAINTENANCE AND LUBRICATION

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of t he vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out.

1. Set the handlebars in a straight-ahead position.

NOTE: The steering frog can be

used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

2. Place stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration.

3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle (2).

4. Measure the distance from

the string to the rim at the front and rear of the front rim (3). Rear measurement should be 1/16″ -1/8″ (.2to.3cm) more than the front measurement.

NOTE: If you discover improper alignment, see your Polaris dealer

for service.

MAINTENANCE AND LUBRICATION

Brakes

The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting.

The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation, such as in hilly country or in muddy terrain.

WARNING

1. Always maintain brake fluid at an adequate level (see page 35).

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

NOTE: Under normal operation, the diaphragm extends into the

reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill.

MAINTENANCE AND LUBRICATION

Brakes

1. Check the brake system for fluid leaks.

2. Check the brakes for excessive travel or spongy feel.

3. Check the friction pads for wear, damage and looseness.

4. Check the security and surface condition of the disc.

NOTE: Pads should be changed when

worn to 3/64″ (.1 cm).

3/64″ (.1 cm)

Auxiliary Brake

The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right footrest. The hydraulic auxiliary brake system requires no adjustment.

NOTE: Since this is a rear brake only, it will not be as effective as

the all-wheel single lever system.

MAINTENANCE AND LUBRICATION

Steering Assembly

The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension.

NOTE: Accessory springs are

available through your Polaris dealer.

Throttle Cable Freeplay

Throttle cable freeplay is adjusted at t he handlebar.

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3).

2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever.

NOTE: While adjusting freeplay, be sure to flip the throttle lever back

3. Tighten the locknut and slide the boots over the cable adjuster until

and forth.

they touch at the midpoint of the adjuster.

MAINTENANCE AND LUBRICATION

Handlebars

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service.

The handlebars can be adjusted for rider preference.

1. Remove the handlebar cover to access the handlebar bolts (1).

2. Loosen the four bolts.

3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

4. Torque the two front bolts to 10-12 ft. lbs. (14-17 Nm), then torque the two rear bolts. A gap of up to 1/8” will remain at the rear bolts.

MAINTENANCE AND LUBRICATION

Carburetor

IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation. Although this power cannot be regained, adjustments to t he carburetor and drive system can be made to allow more efficient operation. Optional jets, available from your Polaris dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.)

NOTE: Continuous operation of the engine without proper jetting

when required can cause poor performance, overheating and engine or PVT damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area.

If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted.

1. Warm up the engine by running the vehicle for approximately five minutes.

2. Place the transmission in gear and engage the parking brake.

3. Adjust the carburetor idle screw (1) either in or out until the desired idle RPM is reached. Refer to the specifications section beginning on page 104 for the proper setting.

NOTE: Turn the screw in (clockwise) to raise

RPM. Turn the screw out (counterclockwise) to lower RPM.

MAINTENANCE AND LUBRICATION

Wheels

WARNING

Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.

Maintain proper tire pressure as described on the decal on your ATV and in your owner’s manual.

Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

Wheel Removal

1. Stop the engine, place the transmission in gear and l ock the parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

4. Remove the wheel nuts and remove the wheel.

MAINTENANCE AND LUBRICATION

Wheels

Wheel Installation

1. Place the transmission in gear and lock the parking brake.

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer.

2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.

3. Install the wheel nuts and finger tighten. On vehicles with tapered rear wheel nuts, make sure the tapered ends of the nuts fit into the tapers on the wheels.

4. Lower the vehicle to the ground.

5. Torque the nuts to s pecification.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they’ve been loosened for maintenance.

Front

Item Specification

Front Wheel Nuts 27 ft. lbs. (37 Nm)

Rear Wheel Nuts 50 ft. lbs. (68 Nm)

Rear

50 ft. lbs.

(68 Nm) 27 ft. lbs. (37 Nm)

MAINTENANCE AND LUBRICATION

Wheels

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration.

1/8I (.3 cm)

WARNING

Operating the vehicle with worn tires will increase the possibility of skidding, which could lead to loss of control and serious injury or death. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less.

WARNING

Use of non-standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death. Maintain proper tire pressure as outlined in this owner’s manual. When replacing a tire always use original equipment size and type.

MAINTENANCE AND LUBRICATION

Rear Drive Chain Slack

CAUTION

Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components. Always make sure the slack is within the stated specifications.

Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three positions. At this point the chain should have 3/16″-3/8″ (.48 cm - .95 cm) deflection. Use the following procedure if adjustment is required.

3/16″-3/8″ (.48 cm - .95 cm)

1. Remove the chain guard.

2. Loosen the chain guide.

3. Loosen the two eccentric locking bolts (1).

4. Loosen the caliper mounting bolt located on the left side of the swing arm.

5. Insert a pin punch (2) through the sprocket hub and into the eccentric housing.

MAINTENANCE AND LUBRICATION

Rear Drive Chain Slack

6. Roll the ATV forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1).

7. Tighten the eccentric locking bolts to 30 ft. lbs. (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. lbs. (20 Nm)

9. Remove the pin punch.

10. Roll the A TV forward, checking chain tension in several places around the chain.

NOTE: The chain is adjusted correctly when the tightest portion of

11. Position the chain guide to allow 1/8” (3mm) clearance and tighten

12. Reinstall the chain guard.

the chain has approximately 3/8” (10mm) deflection.

the retaining bolt to 5 ft. lbs. (7 Nm).

MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle (1) is located on the left side of the machine. The fluid level must be maintained between the minimum and maximum marks on the bottle (when the fluid is cool).

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the recovery bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator.

Some coolant level drop on new machines is normal, as the system is purging itself of trapped air. Observe coolant l evels and maintain as recommended by adding coolant to the recovery bottle.

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 107 for t he part numbers of Polaris products.

NOTE: Polaris Premium 60/40 is already premixed and ready to use.

Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

MAINTENANCE AND LUBRICATION

Engine Cooling System

WARNING

Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.

Radiator Coolant Level

NOTE: This procedure is required only if

the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.

1. Remove the front panel to access the radiator pressure cap (1). Remove the cap.

2. If coolant is low, use a funnel and

slowly add coolant through the radiator filler neck.

3. Reinstall the pressure cap and secure the front panel.

4. Fill the coolant recovery bottle to the upper mark on the bottle.

5. Check the coolant level in the bottle frequently, adding coolant as needed until the level stabilizes.

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly. Contact your dealer for the correct replacement part.

MAINTENANCE AND LUBRICATION

Lights

When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.

WARNING

Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality.

Hot components can cause serious burns to skin. Do not service the headlamps until they’ve cooled sufficiently.

Headlight Lamp Replacement

1. Remove the wire harness connector from the back of the headlight.

2. Grasp the bulb housing and turn it counterclockwise to remove the bulb.

3. Apply dielectric grease to the light bulb socket before installing the new bulb. Install the replacement bulb into headlight housing and rotate clockwise firmly.

NOTE: The bulb must be positioned so the harness installs into the

4. Reinstall the connector to the back of the headlight..

lamp at the bottom.

High Beam Adjustment

The headlight beam can be adjusted vertically.

1. Position the ATV on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall.

2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

3. Start the engine and turn the headlight switch to high beam.

4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be aimed 2” (5.1 cm) below the mark placed on the wall.

NOTE: Include rider weight on the seat when measuring.

5. Loosen the pivot bolt and adjust the beam to the desired position.

6. Tighten the bolt and torque to 60 in. lbs. (7 Nm).

MAINTENANCE AND LUBRICATION

Lights

Taillig h t /Brakelight Lamp Replacement

If the taillight/brakelight does not work the lamp may need to be replaced.

1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly.

2. Remove the lamp (1).

3. Apply dielectric grease to the socket and install the new lamp.

4. Test the taillight/brakelight for proper operation.

5. Reinstall the gasket and lens cover.

Indicator Lamp Replacement

1. Remove the instrument panel, if necessary, to access the back of the indicator panel.

2. Using a small, straight-blade screwdriver, turn the base of the bulb 1/4 turn counterclockwise.

3. Using a needle-nose plier or similar tool, pull the lamp out of the indicator panel housing.

4. Insert the new bulb and seat it by turning it 1/4 turn clockwise.

5. Reinstall the instrument panel if removed.

MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

1. Remove the seat, release the clips, and remove the air box cover.

2. Loosen the clamp and remove the filter.

3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry.

4. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.)

5. Reinstall the filter into the air box and tighten the clamp. Do not over tighten the clamp, as filter damage could occur.

Breather Filter/Hose

CAUTION

Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service.

1. Remove the clamps and pull the filter (1) out of the hoses.

NOTE: It’s not necessary to remove the

lower hose from the engine.

2. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace if needed.

3. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

4. Reinstall the filter and secure the clamps.

NOTE: The filter is effective with the arrow pointing in either

direction.

MAINTENANCE AND LUBRICATION

Spark Plugs

CAUTION

Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 104

Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.

WARNING

A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection.

1. Normal

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.

overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 14 ft. lbs. (19 Nm).

MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

1. Move the ATV to dry land or at the very least, to water below the footrests.

2. Check the airbox for any water. Drain and dry it if water is present.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Turn the engine over several times using the electric start.

6. Loosen the carburetor drain screw (1).

7. Dry the spark plug and reinstall, or replace it with a new plug.

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

10. Attempt to start the engine. If necessary, repeat the drying procedure.

11. Take the ATV to your dealer for s ervice as soon as possible, whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT, follow the procedure

on page 95 for drying out the PVT.

MAINTENANCE AND LUBRICATION

Recoil Housing

To prevent possible engine damage, always drain the recoil housing (1) afteroperatingtheATVinverywet conditions. This should also be done before storing the ATV.

Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water.

The drain screw is located at the bottom of the recoil housing. Use a wrench to remove the screw. Be sure to reinstall the screw after draining the housing.

NOTE: Do not open the crankcase drain unless the engine has

ingested water. On 4-cycle engines, some engine oil will be lost if the crankcase drain is opened.

MAINTENANCE AND LUBRICATION

PVT System

The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt “pinch.” This begins to occur at speeds of less than 5 MPH, due to the system’s dependence on engine speed.

For example, when operating at a ground speed of 3 MPH, the engine would be running at only about 1500 RPM, with an engagement speed of about 1400 RPM. Whenever operating this close to the engagement point, the engine may be running at a speed too low to provide the adequate “pinch” needed to prevent incomplete engagement. Incomplete engagement creates excessive heat that can destroy belts and clutch covers. In some cases, excessive clutch wear and damage may result.

If the ATV will be operated for extended periods below 5 MPH, or for towing loads, we recommend that you install a one tooth smaller counter shaft sprocket to raise the operating RPM far enough above the engagement RPM to reduce heat caused by incomplete engagement. Reducing the temperature inside the clutch cover extends the life of the PVT components (belt, cover, etc.).

NOTE: Avoid heavy pu lling and extended low-speed

operation.

MAINTENANCE AND LUBRICATION

PVT System

WARNING

Failure to comply with the instructions in this warning can result in severe injury or death.

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:

Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual.

This PVT system is intended for use on Polaris products only. Do not install it in any other product.

Always make sure the PVT housing is securely in place during operation.

PVT Drying

There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating:

1. Remove the drain plug and allow the water to drain. Reinstall the drain plug.

2. Start the engine and shift the transmission into neutral. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

3. Allow the engine RPM to settle to idle speed, then shift the transmission to the lowest available range.

4. Test for belt slippage. If the belt slips, repeat the process.

5. Take the vehicle to your dealer for service as soon as possible.

MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.

Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.

Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area. Exhaust contains

poisonous carbon monoxide gas. Never go under the vehicle while it’s inclined.

1. Remove the arrestor clean-out plug (1) from the bottom of the muffler.

2. Place the transmission in neutral and start the engine.

3. Purge carbon from the system by momentarily revving the engine several times.

4. If carbon is expelled, cover or plug the exhaust outlet (2) and rap on the pipe around the cleanout plug while revving the engine several more times.

5. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot higher than t he front. Set the parking brake and block the wheels. Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved.

6. Stop the engine and allow the arrestor to cool. Reinstall the arrestor plug and remove the outlet cover or plug.

MAINTENANCE AND LUBRICATION

Battery

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

Battery Removal

1. Disconnect the hold-down strap holding the battery in position, and remove battery cover.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Lift the battery out of the ATV.

Battery Installation

When installing a new battery, m ake sure it’s fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 98 before installing the battery.

1. Ensure that the battery is fully charged.

2. Set the battery in the battery holder.

3. Connect and tighten the red (positive) cable first.

4. Connect and tighten the black (negative) cable last.

5. Reinstall the battery cover and attach the hold-down strap.

6. Verify that cables are properly routed.

Polaris Scrambler 500 4x4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual