Polaris Scrambler 9921620 User Manual

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 Quadricycles 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 2007 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.

2008 Scrambler 500 2X4 International Owner’s Manual P/N 9921620

Printed in U.S.A.

TABLE OF CONTENTS

Know Your Vehicle 5.........................

Safety 6.....................................

Features and Controls 31.....................

Operation 41.................................

Emission Control Systems 59.................

Maintenance 60..............................

Specifications 108............................

Polaris Products 111.........................

T roubleshooting 1 12.........................

Warranty 116................................

Maintenance Log 1 18.........................

Index 121....................................

KNOW YOUR VEHICLE

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

Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.

Vehicle Identification Numbers

Record your vehicle’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

31XX

Vehicle Model Number:

Frame VIN (1):

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

Key Number (2):

SAFETY

Operator Safety

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

The safety alert symbol, 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

Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris Quadricycle is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

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

Safety Training

When you purchased your new Quadricycle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis.

If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.

Age Restrictions

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

Equipment Modifications

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

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

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

SAFETY

Operator Safety

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 a Quadricycle without proper instruction. Tak e a

training course. Beginners should receive training from a certified

instructor. Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com.

S Never allow anyone under 16 years of age to operate this Quadri-

cycle.

S Never permit a guest to operate the Quadricycle unless t he guest has

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

S Never operate a Quadricycle without wearing an approved helmet

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

S Never consume alcohol or drugs before or while operating a Quadri-

cycle.

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 Quadricycle before each use to make sure it’s in

safe operating condition. Always follow t he 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 Quadricycle 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 Quadricycle inspected by an authorized Polaris

dealer if it’s been involved in an accident.

S Never operate on hills too steep for the Quadricycle or for your abili-

ties. 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 Quadricycle. Never attempt to turn the Quadricycle around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual. Avoid 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 Quadricycle is pointed straight uphill. Turn the Quadricycle 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 Quadricycle through deep or fast-flowing water.

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

SAFETY

Operator Safety

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 the vehicle before oper-

ating 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 vehicle, and

always maintain proper tire pressure.

S Never modify a Quadricycle through improper installation or use of

accessories.

S Never exceed the stated load capacity for your vehicle. Cargo must

be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

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

prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT QUADRICYCLE SAFETY, contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com.

SAFETY

Operator Safety

WARNING

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

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

HOW TO AVOID THE Never operate a Quadricycle without proper instruction. Take a

training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www.polarisindustries.com.

HAPPEN

HAZARD

WARNING

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

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

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

HOW TO AVOID THE Never allow anyone under 16 years of age to operate this vehicle.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Carrying a passenger on a

Quadricycle. WHAT CAN Carrying a passenger

greatly reduces the operator’s ability to balance and control the Quadricycle, 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

Operator Safety

WARNING

POTENTIAL HAZARD Operating this Quadricycle

without wearing an approved helmet, eye protection and protective clothing.

WHAT CAN Operating a Quadricycle

without an approved helmet increases the risk of a severe head injury or death in the event of an accident.

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

HOW TO AVOID THE 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 Quadricycle 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 a Quadricycle could result in an accident causing severe injury or death.

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

Quadricycle.

HAPPEN

HAZARD

WARNING

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

control of the Quadricycle, which can result in an accident. HOW TO AVOID THE Always operate the Quadricycle 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 Quadricycle before operating. Failure to properly maintain the Quadricycle. WHAT CAN Poor maintenance increases the possibility of an accident or

equipment damage. HOW TO AVOID THE Always inspect your Quadricycle 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 Quadricycle.

If the operator’s foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury.

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

footrests of the Quadricycle during operation.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Failure to use extra

caution when operating the Quadricycle 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 Quadricycle 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 Quadricycle or for your

abilities. Never operate the Quadricycle 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 Quadricycle 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

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

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

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 53.

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

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

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 Quadricycle around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page

54. Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill. When crossing the side of a 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 Quadricycle.

HAPPEN

THE

hill:

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 Quadricycle 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 vehicle is pointed

straight uphill. Turn the vehicle around and remount, following the procedure

described in the owner’s manual. See page 54.

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 vehicle 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 Quadricycle 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 vehicle. When it’s safe to proceed, back slowly.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the Quadricycle 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 Quadricycle through deep or fast-flowing

water. If it’s unavoidable to enter water that exceeds the recommended maximum depth (see page 55), travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. 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 Quadricycle with improper tires, or with improper

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

improper or uneven tire pressure, could cause loss of control or accident.

HOW TO AVOID THE Always use the size and type of tires specified for the vehicle. Always maintain proper tire pressure as specified.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

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

Quadricycle may cause changes in handling which could lead to an accident.

HOW TO AVOID THE Never modify the Quadricycle through improper installation or use

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

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Overloading the Quadricycle 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 vehicle. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a

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

cargo or pulling a trailer. See page 46.

HAPPEN

HAZARD

WARNING

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

fall through the ice. HOW TO AVOID THE Never operate the Quadricycle 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

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.

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 vehicle is stored or parked.

WARNING

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

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

SAFETY

Safety Decals and Locations

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

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

Discretionary Warning (1)

WARNING S Never operate this vehicle on

HILLS steeper than 25 degrees

25°. To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually.

S REVERSE operation can be

dangerous, even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

S Use OVERRIDE for reverse

speed limiter with caution. To prevent loss of control, never activate override button with open throttle.

S PARKING BRAKE may relax when used

for more than 5 minutes. When parking on grades, leave shift in forward.

Clutch Cover Warning (2)

WARNING NO STEP

S Moving parts hazard under belt-clutch guard. To prevent serious injury, do

not operate vehicle with guard removed.

S Do not modify engine or clutch. Doing so can cause part failure, possible im-

balance, and excessive engine RPM, which can result in serious injury or death.

SAFETY

Safety Decals and Locations

General Warning (3)

WARNING Improper ATV use can result in

SEVERE INJURY or DEATH ALWAYS USE AN APPROVED

HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR

ALCOHOL NEVER operate:

S without proper training or instruction S at speeds too fast for your skills or the

conditions

S on public roads -- a collision can occur with

another vehicle

S with a passenger -- passengers affect balance and steering and increase risk

of losing control

ALWAYS: S use proper riding techniques to avoid vehicle overturns on hills and rough

terrain and in turns

S avoid paved surfaces -- pavement may seriously affect handling and control LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS

AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.

SAFETY

Safety Decals and Locations

No Passenger Warning (4)

WARNING NEVER ride as a passenger. Passengers can cause a

loss of control, resulting in SEVERE INJURY or DEATH.

Age16Warning(5)

WARNING Operating this ATV if you

are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16.

Tire Pressure/Load Warning (6)

WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control

resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 3 (20.7) MAXIMUM WEIGHT CAPACITY 305 LBS. (138 kg).

INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES Reduce speed and allow greater distance for braking when carrying cargo.

Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible, and firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is best. For stability on rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack.

Read Owner’s Manual for more detailed loading information.

SAFETY

Safe Riding Gear

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

1. Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

051039

0006.031

2. Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V--8, Z87.1, or CE. Make sure protective eye wear is kept clean.

3. Glo ves

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

4. Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

5. Clothing

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

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.

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.

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

vehicle, including the lights.

RUN OFFOFF

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

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 vehicle is used.

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

1. Transmission Neutral Indicator

2. Transmission Reverse In dicator

3. HighTempWarning(displays if engine overheats)

the key off to prevent battery drain.

FEATURES AND CONTROLS

Throttle Lever

WARNING

Do not start or operate a Quadricycle with sticking or improperly

operating throttle controls, which could cause an accident and

lead to severe injury or death.

Always contact your dealer for service repairs if throttle problems

arise.

Failure to check or maintain proper operation of the throttle

system can result in an accident if the throttle lever sticks during

operation.

Always check the lever for free movement and return before

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

WARNING

The Electronic Throttle Control (ETC) stops the engine in the

event of a throttle system malfunction and is provided f or 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 vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever.

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

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

FEATURES AND CONTROLS

Brakes

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

The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This “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 vehicle must be on level

ground with the handlebars straight. If the fluid level is low add DOT 4 brake fluid only. DO NOT OVERFILL. See page 1 11 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 vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating.

Locking the Parking Brake

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

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

3. To release t he 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 long period of time. Al-

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the vehicle if leav-

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

S Never depend on the parking brake alone if the vehicle 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 the main system becomes inoperative.

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

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

FEATURES AND CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 for correct choke and throttle settings during starting.

Fuel Valve

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

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if main supply is exhausted.

NOTE: There’s about a 7 to 10 mile

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

Always return the valve to the ON position after refueling.

Fuel Tank

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

Fuel Filter

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

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 vehicle 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 lock the parking brake (see page 36).

2. Shift the transmission into neutral.

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

NOTE: If the engine is cold, use the choke as outlined on page 43.

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

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

make the 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.

OPERATION

Break-In Period

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

CAUTION

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

Engine an d Drivetrain Break-in

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

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

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

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

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

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 42.

6. Pull only light loads.

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

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, 74

Brake fluid Ensure proper level 35

Auxiliary brake Ensure proper operation 75

Front suspension Inspect, lubricate if necessary 64

Rear suspension Inspect, lubricate if necessary 64

Steering Ensure free operation --

Tires Inspect condition and pressure 81

Wheels / fasteners Inspect, ensure fastener tightness 80

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

Fuel and oil Ensure proper levels 66

Coolant level (if applicable) Ensure proper level 84

Coolant hoses (if applicable) Inspect for leaks --

Throttle Ensure proper operation 33, 76

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 88

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

72, 82

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.

1. Position the vehicle on a level surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

NOTE: The starter interlock will

prevent the engine from starting if the transmission is in gear and the brake is not engaged.

4. Turn the fuel valve on.

5. Sit on the vehicle.

NOTE: Do not use the choke if starting a warm engine. Excessive

use of the choke can cause the spark plug to become wet fouled.

6. If the engine is cold, pull the choke knob out until it stops (1).

NOTE: The variable choke is fully on when the knob is pulled

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

NOTE: If the knob doesn’t stay where positioned, increase the

tension by rotating the tension adjusting nut (2) clockwise.

OPERATION

Starting the Engine

7. Move the engine stop switch to RUN.

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

8. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

9. If the engine does not start, release the key and wait five seconds. Activate the starter for another five seconds. Repeat this procedure until the engine starts.

NOTE: If a warm engine has cooled to a point where it does not

readily start, intermittent use of the choke button (pulled half way out) may be necessary. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in starting. Release the throttle lever immediately after the engine starts. If the engine does not start and all conditions are favorable, change the spark plug and try again.

10. If the engine slows, position the choke knob half way in to allow proper engine warm up. Vary the engine RPM slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke completely in.

CAUTION

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

OPERATION

Driving Safely

Driving Procedures

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

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

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

4. Release the parking brake.

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

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

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

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

NOTE: Practice making turns at slow speeds before attempting to

turn at faster speeds.

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 t he skid and shifting your body weight forward.

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 parking brake.

If the vehicle begins rolling backwards:

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

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

Dismount on uphill side, or to either side if vehicle is pointed straight uphill. Turn the vehicle around and remount, following the procedure described on page 54.

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 transmission 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 vehicle 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 60. 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 91. 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 vehicle is equipped with a reverse speed limiter.

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

CAUTION

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

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. Lock 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 governmental noise level requirements.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.

Electromagnetic Interference

This spark ignition system complies with USA requirements, Canadian ICES--002 and European directives 89/336/EEC and 97/24/EC.

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on page 118.

NOTE: Service and adjustments are important for proper vehicle

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

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 the 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 42.

as needed

coolant every 2 years

dielectric grease if replacing

check often if operating in wet conditions

Remarks

MAINTENANCE

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

(if applicable)

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 level; change yearly

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

Periodic Maintenance Chart

MAINTENANCE

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 T iming 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

Lubrication Recommendations

Always check and change fluids and lubricate greaseable components at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Items not listed in the chart should be lubricated at the General Lubrication interval.

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

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

Lubrication Chart Key

" 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 s ubmerging

∆ When suspension action becomes stiff, or after washing

Item Lube Method

Engine Oil PS-4 PLUS Performance

Brakes DOT 4 fluid only Maintain level between fill lines.

Drive chain(s) O-ring chain lube or SAE

(1) Transmission AGL Synthetic

(2) Swing Arm Bushings

(3) Tie Rod Ends

(4) Axle Housing

Synthetic 2W-50

80/90

Gearcase Lube

"L Grease

"L∆ Grease

"L Grease

Add to proper level on dipstick.

See page 35.

Lubricate.

Maintain as recommended on page 70.

Locate fittings on swing arm and grease with grease gun.

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

Locate fittings on swing arm and grease with grease gun.

Lubrication Recommendations

(1)

(3)

(4)

MAINTENANCE

(2)

MAINTENANCE

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Always change the oil filter whenever changing oil.

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer’s recommendations for ambient temperature operation.

See page 111 for the part numbers of Polaris products.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Oil Ch eck

1. Position the vehicle 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. Wipe the dipstick dry with a clean cloth. Reinstall it and screw it completely in.

NOTE: The dipstick must be

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

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

ADD 8 OZ. NORMAL FULL

MAINTENANCE

Engine Oil

Oil an d Filter Chan ge

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

Engine Oil

Oil an d Filter Chan ge

9. Place shop towels beneath the 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. Place the gear selector in neutral. Lock the parking brake.

16. Prime the oil pump using the procedure on page 69.. Then stop the engine and inspect for leaks.

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

18. Dispose of used filter and oil properly.

Engine Oil

Oil an d Filter Chan ge 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 is 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

Transmission Oil

Always check and change the transmission oil at t he intervals outlined in the Periodic Maintenance Chart beginning on page 60. Maintain the oil level within the SAFE operating range on the dipstick. We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 111 for the part numbers of Polaris products.

Oil Ch eck

The transmission oil dipstick (1) is located on the right side of the vehicle.

1. Position the vehicle on a level surface.

2. Remove the dipstick and wipe it clean.

3. Reinstall the dipstick completely, then remove it and check the level.

4. Add the recommended lubricant to bring the level into the safe operating range (2).

5. Reinstall the dipstick.

MAINTENANCE

Transmission Oil

Refer to the specifications section beginning on page 108 for transmission oil capacity.

Oil Change

1. Position the vehicle on a level surface.

2. Place a drain pan beneath the transmission oil drain plug area.

3. Loosen the jam nut (A).

4. Turn the adjuster bolt (B) in to allow the removal of the drain plug (C).

5. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings.

6. After the oil has drained completely, install a new sealing washer and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

7. Turn the adjuster bolt (B) out until it touches the frame, and then turn an additional 1/2 turn.

8. Tighten the jam nut securely while holding the adjuster bolt.

9. Remove the dipstick. Add the recommended lubricant until the oil level is between the upper and lower limits. Do not overfill.

10. Reinstall the dipstick.

11. Check for leaks.

MAINTENANCE

Drive Chain

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

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

Regularly lubricate the drive chain with Polaris Chain Lube, an SAE 80-90 lube or an approved o-ring chain s pray lube. See page 111 for the part numbers of Polaris products.

CAUTION

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

MAINTENANCE

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 the vehicle. The recommended toe alignment is 1/8″ -1/4″ (3-6 mm) toe out.

1. Position the vehicle on a level surface.

2. Set the handlebars in a straight-ahead position and secure them in this position.

3. Place a chalk mark on the center line of the front tires approximately 10″ (25.4 cm) from the floor, or as close to the hub/axle center line as possible. Make sure both marks are the same distance from the floor.

4. Measure the distance between the marks and record the measurement (A).

5. Move the vehicle until the chalk marks are at the rear of the tires, even with the hub/axle centerline.

6. Measure the distance between the marks and record the measurement (B).

7. Subtract measurement B from measurement A. The difference is the vehicle toe-out alignment.

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

for service.

MAINTENANCE

Brakes

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

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

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.

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 4 brake fluid. Do not overfill.

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.

MAINTENANCE

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

Steering Assembly

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

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

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

NOTE: Accessory springs are

available through your Polaris dealer.

Throttle Cable Freeplay

1. Locate the throttle cable adjuster at the handlebar.

2. Squeeze the end of the rubber boot (A) and slide it far enough to expose the end of the inline cable adjuster (B).

3. Loosen the adjuster locknut (C).

4. Rotate the boot to turn the adjuster until 1/16″ to 1/8″ (1.5-3 mm) of freeplay is achieved at the thumb lever.

NOTE: Move the throttle lever back

and forth while adjusting.

5. Tighten the locknut.

6. Reinstall the boot(s) to their original position.

NOTE: Engine RPM should not

increase when steering is turned full left or right. Readjust cable freeplay if this occurs.

1/16″ to 1/8″

(1.5-3 mm)

MAINTENANCE

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

Carburetor

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

NOTE: Continuous operation of the engine without proper jetting

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

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

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

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

3. Adjust the carburetor idle screw (1) either in or out until the desired idle RPM is reached. Refer to the specifications section beginning on page 108 for the proper setting.

NOTE: Turn the screw in (clockwise) to raise

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

MAINTENANCE

Wheels

WARNING

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

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

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

or less.

Wheel Removal

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

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

Wheels

Wheel Installatio n

1. Place the transmission in gear and l ock t he 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 specification.

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

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

Rear Drive Chain Slack

CAUTION

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

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

3/16″-3/8″ (.48 cm - .95 cm)

1. Remove the chain guard.

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

Rear Drive Chain Slack

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

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 vehicle 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

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 levels and maintain as recommended by adding coolant to the recovery bottle.

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

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 111 for the part numbers of Polaris products.

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

Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

MAINTENANCE

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 s ecure 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

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

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

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

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

NOTE: Include rider weight on the seat when measuring.

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

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

MAINTENANCE

Lights

Taillight/Brakelight L a mp 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 L amp 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

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 i n 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 i nto 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

Spark Plugs

Spark Plug Recommendations

CAUTION

Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 108

Refer to the specifications section beginning on page 108 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

Plug Condition Torque Specification

New Spark Plug 9-11 ft. lbs. (12-15 Nm)

Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 90.

WARNING

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

1. Remove the spark plug cap.

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

3. Reverse the procedure for spark plug installation. Torque to specification.

MAINTENANCE

Spark Plugs

Spark Plug Inspection

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This 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

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

Wet Fouled Plug

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

Recoil Housing

To prevent possible engine damage, always drain the recoil housing (1) after operating the vehicle in very wet conditions. This should also be done before storing the vehicle.

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

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 Quadricycle to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle 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 vehicle to your dealer for service 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 93 for drying out the PVT.

MAINTENANCE

PVT System

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

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

NOTE: Avoid heavy p ulling and extended low-speed

operation.

MAINTENANCE

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

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 the front. Lock the parking brake and block the wheels. Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved.

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

MAINTENANCE

Battery

Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

Conventional Battery

Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

Antidote:

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

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

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

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

MAINTENANCE

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. On conventional batteries, remove the battery vent tube.

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

4. Disconnect the red (positive) battery cable next.

5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle.

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on pages 99-101 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).

NOTE: The vent tube must be free of obstructions and securely

installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

WARNING

Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

4. On conventional batteries, coat the terminals with dielectric grease or petroleum jelly.

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

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

7. Install the battery cover.

8. Secure the battery hold-down strap.

9. Verify that cables are properly routed.

NOTE: Cables should be safely tucked away at the front and rear of

the battery.

MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

NOTE: Power plug leads may need to be bent down so that the

battery cover can be installed.

NOTE: Battery charge can be maintained by using a Polaris Battery

Tender charger or by charging about once a month to make up for normal self-discharge. Battery T ender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See page 111 for the part numbers of Polaris products.

Polaris Scrambler 9921620 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual