Polaris Scrambler 9922077, Scrambler 500 2X4 User Manual

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Pantone 425 C

WARNING

Improper vehicle 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.

READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

For your nearest Polaris dealer, visit www.polarisindustries.com

Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A.

Part No. 9922077 Rev 02 Printed in U.S.A.

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• Quadricycles

• RANGER utility vehicles

• Victory motorcycles Always follow the instructions and recommendations in this manual.

The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Please see your dealer for all of your service needs during (and after) the warranty period.

For more information about Polaris, visit us online at www.polarisindustries.com.

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in Taiwan 2009 Scrambler 500 2X4 International Owner’s Manual P/N 9922077

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . 22

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Emission Control Systems . . . . . . . . . . . . . . . 49

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 102

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 104

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 105

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 111

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

INTRODUCTION

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

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating the vehicle.

• Never operate this vehicle without proper instruction. Take a training course.

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

• This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited.

INTRODUCTION

####

VIN

Key Number

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

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

Key Number: ___________________________________________________________

SAFETY

Safety Training

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

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

Equipment Modifications

The warranty on your Polaris vehicle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.

The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers and large racks may change vehicle handling. Use only Polaris-approved accessories. Know their function and effect on the vehicle.

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet

Always wear a helmet that meets or exceeds established safety standards.

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

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

SAFETY

Safe Riding Gear

Eye Protection

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

Gloves

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

Boots

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

Clothing

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

SAFETY

WARNING

Operator Safety

Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating this vehicle.

Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com.

Never permit others to operate this vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

Never allow anyone under 16 years of age to operate this vehicle.

SAFETY

Operator Safety

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

• Turn the fuel valve off whenever the vehicle is stored or parked.

Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas.

Always inspect your vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 33.

Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

SAFETY

Operator Safety

Never consume alcohol or drugs before or while operating this vehicle.

Keep both hands on the handlebars. Keep both feet on the footrests.

Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.

SAFETY

Operator Safety

Never carry a passenger on the rear rack. Ejection from the vehicle or contact with moving components can result in serious injury or death.

Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control, accident and/or injury. Avoid sudden turns or swift movement of the handlebars.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

SAFETY

Operator Safety

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle

overturn. See page 37.

Never attempt jumps or other stunts.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 43.

Operator Safety

Always follow the procedures outlined in this manual for driving on hills. See page 39. Never operate on hills too steep for this vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills

steeper than 25°. Always follow the procedures outlined in this

manual for driving downhill and for braking on hills. See page 41.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See

page 42.

SAFETY

Always follow the procedures outlined in this manual for crossing the side of a hill. See page

40. Never attempt to turn this vehicle around on

any hill until you've mastered (on level ground) the turning technique outlined in this manual.

SAFETY

Operator Safety

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Always follow the procedures outlined in this manual for driving in reverse. See page 45.

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

Always follow the procedures outlined in this manual for operating over obstacles. See page 44.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page

38.

SAFETY

Operator Safety

Never operate this vehicle on a frozen body of water.

Never modify a Quadricycle through improper installation or use of accessories.

Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

If this vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

For more information about Quadricycle safety, contact

an authorized Polaris Quadricycle dealer or visit the

Polaris web site at www.polarisindustries.com.

SAFETY

Safety Labels and Locations

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

If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label.

General Warning

WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

• on public roads - a collision can occur with another vehicle

• with a passenger - passengers affect balance and steering and increase risk of losing control

ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175376

SAFETY

General

Warning

Discretionary

Warning

Safety Labels and Locations

Discretionary Warning

WARNING

• Never operate this ATV on HILLS steeper than 25 degrees 25°. To pre-

vent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill.

• REVERSE operation can be dangerous even at low speeds. Steering

becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.

7175511

SAFETY

“No Passenger”

Warning

Clutch Cover

Warning

Age 16

Warning

Tire Pressure/Load

Warning

Safety Labels and Locations

“No Passenger” Warning

WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or

DEATH.

Tire Pressure/Load Warning

WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 4.0 psi (27.6 kPa) Rear: 3.0 psi (20.7 kPa)

• Maximum weight capacity: 275 lbs. (125 kg)

7175378

7175443

SAFETY

Safety Labels and Locations

Age 16 Warning

WARNING Operating this ATV if you are under the age of 16 increases your chance of

severe injury or death. NEVER operate this ATV if you are under age 16.

7175374

Clutch Cover Warning

WARNING

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not

operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible

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

NO STEP

7172563

Reverse Override Warning

WARNING Improper use of override button can lead to loss of control resulting in severe

injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse.

7175486

FEATURES AND CONTROLS

Override

Switch

Main Key Switch

Engine

Stop Switch

Headlight Switch

OFF OFFRUN

Switches

Override Switch

This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and press the override switch.

WARNING! Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override switch.

The override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on.

Engine Stop Switch

Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off.

Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 34 for starting procedures.

FEATURES AND CONTROLS

Neutral Indicator

Reverse Indicator

High Temperature Warning

(displays if engine overheats)

Switches

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights.

Indicator Lights

With the engine running, verify the function of all indicator lights before each use of the vehicle.

Tip: The taillight is on whenever the main switch (key) is on. Turn the key off to

prevent battery drain.

FEATURES AND CONTROLS

Throttle Lever

Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.

Do not start or operate a vehicle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.

FEATURES AND CONTROLS

Brake Lever

Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.

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

Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.

Inspect and maintain the brake fluid level as outlined in this manual. See page 63.

FEATURES AND CONTROLS

Parking Brake

1. Place the transmission in

gear.

2. Squeeze and release the

brake lever two or three times, then squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake

lever. It will return to its unlocked position.

Operating the vehicle while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.

The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the vehicle if leaving it parked on a hill. Another option is to park the vehicle in a sidehill position. Never depend on the parking brake alone if the vehicle is parked on a hill. Always block the wheels to prevent rolling.

FEATURES AND CONTROLS

Auxiliary

Foot Brake

Auxiliary Foot Brake

Aggressively applying the auxiliary rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.

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

The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.

The auxiliary foot brake is located on the inside of the right footrest. Operate this brake with your right foot.

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

FEATURES AND CONTROLS

Fuel

Ta n k

Cap

Fuel

Valv e

OFF ON RES

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 34 for correct choke and throttle settings during starting.

Fuel Tank Cap

Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface.

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel.

Fuel Valve

The fuel valve is located on the left side of the vehicle, below the fender.

ON: For normal operation. OFF: For vehicle storage

and when transporting. RES: Turn the valve to the reserve setting if the main fuel supply is

exhausted. Refuel as soon as possible. Return the valve to the ON position after refueling.

Reserve fuel range is about 7-10 miles (11-16 km).

Fuel Filter

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

FEATURES AND CONTROLS

Gear

Selector

Transmission Gear Selector

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

F: Forward Gear N: Neutral R: Reverse

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

NOTICE: Shifting gears with the engine

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

speed above idle or while the vehicle is moving could cause transmission damage.

OPERATION

Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

Break-In Period

The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part 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.

NOTICE: Do not operate at full throttle or high speeds during the first three

hours of use.

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 28. Always exercise

extreme caution whenever handling gasoline.

2. Check the oil level. See page 56. Add oil as needed to maintain the

level in the proper range.

3. Drive slowly at first. Select an open area that allows room to famil-

iarize yourself with vehicle operation and handling.

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

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 33.

6. Pull only light loads (if equipped with a hitch).

7. Change both the oil and the filter at 20 hours or one month, which-

ever comes first.

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

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

2. Do not allow anyone under 16 years of age to operate this vehicle.

Do not allow anyone with cognitive or physical disabilities to operate this vehicle.

3. Never carry a passenger on this vehicle.

4. Engine exhaust fumes are poisonous. Never start the engine or let it

run in an enclosed area.

5. Avoid sudden turns or swift movement of the handlebars when

operating on pavement.

6. Use caution and drive at reduced speeds in conditions of reduced

visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

7. Drive in a manner appropriate for your skills and operating condi-

tions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.

8. Never consume alcohol or drugs before or while operating this vehi-

cle.

9. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure.

10. Never operate a damaged Quadricycle. After any overturn or acci-

dent, have a qualified service dealer inspect the entire machine for possible damage.

11. Never operate the vehicle on a frozen body of water.

12. Familiarize yourself with all laws and regulations concerning the

operation of this vehicle in your area.

13. Do not touch hot exhaust system components. Always keep com-

bustible materials away from the exhaust system.

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

prevent unauthorized use.

OPERATION

Pre-Ride Checklist

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.

Item Remarks Page

Brake system/lever travel Ensure proper operation 25

Brake fluid Ensure proper level 63

Auxiliary Foot brake Ensure proper operation 27

Front suspension Inspect, lubricate if necessary 55

Rear suspension Inspect, lubricate if necessary 55

Steering Ensure free operation -

Tires Inspect condition and pressure 77

Wheels/fasteners Inspect, ensure fastener tightness 77

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 28

Coolant level Ensure proper level 73

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 24

Indicator lights/switches Ensure operation 22

Engine stop switch Ensure proper operation 22

Drive chain Check condition/slack, lubricate as

Air filter, pre-filter Inspect, clean 80

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

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

Riding gear Wear approved helmet, goggles, and

needed

tric grease when lamp is replaced

protective clothing

23 75

OPERATION

Choke

Knob

Adjusting

Nut

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well-venti-

lated area.

2. Place the transmission in neutral.

3. Lock the parking brake.

Tip: The starter interlock will prevent the engine from starting if the transmission

is in gear and the brake is not engaged.

4. Turn the fuel valve on.

5. Sit on the vehicle.

Tip: Do not use the choke if starting a warm engine. Excessive 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. If the knob doesn't stay where positioned, increase the tension by rotating the tension adjusting nut clockwise.

Tip: 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.

7. Move the engine stop switch to RUN.

8. Do not press the throttle while starting the engine.

OPERATION

Starting the Engine

9. 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.

NOTICE: Operating the vehicle immediately after starting could cause engine

10. If the engine does not start, return the key to the OFF position and

Tip: If a warm engine has cooled to a point where it does not readily start, inter-

11. If the engine slows or stops, position the choke knob half way in to

damage. Allow the engine to warm up for several minutes before operating the vehicle.

wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

mittent use of the choke (knob pulled half way out) may be necessary. If the engine is over-choked when warm, depress the throttle lever fully while 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.

allow proper engine warm up. Vary the engine RPM slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke completely in.

OPERATION

Driving Procedures

1. Wear a helmet and eye protection. See page 8.

2. Sit upright. Keep your feet on the footrests. Keep both hands on the

handlebars.

3. Squeeze the brake lever.

4. Start the engine and allow it to warm up.

5. Shift the transmission into gear.

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

7. Release the brake lever.

8. Slowly squeeze the throttle lever toward the handlebar to begin

driving. Squeeze the throttle lever further to increase speed.

9. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

OPERATION

Turning the Vehicle

To 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. The same leaning technique should be used for turning in reverse.

Practice making turns at slow speeds before attempting to turn at faster speeds.

Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.

OPERATION

Sideways

skid

Turn in

direction of

skid

Driving on Slippery Surfaces

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

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down when entering slippery areas.

3. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

4. Never apply the brakes during a skid. Correct a skid by turning the

handlebars in the direction of the skid and shifting your body weight forward.

OPERATION

25° Maximum

Driving Uphill

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (25°

maximum).

3. Always check the ter-

rain carefully before ascending any hill.

4. Avoid hills with exces-

sively slippery or loose surfaces.

5. Keep both feet on the

footrests.

6. Shift body weight

uphill.

7. Drive at a steady rate of speed to avoid stalling.

8. Never open the throttle suddenly or make sudden gear changes.

9. Never go over the top of a hill at high speed.

10. Be alert. Be prepared to take emergency action. This may include

dismounting quickly.

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 downhill, never apply engine power. Never apply the rear brakes 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 the uphill side, or to either side if the vehicle is pointed straight uphill. Turn the vehicle around and remount, following the procedure described on page 42.

OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid hills with excessively slippery or loose surfaces.

3. Avoid crossing the side of a steep hill.

4. Shift body weight uphill.

5. Keep your feet on the footrests.

6. If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

OPERATION

25° Maximum

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (25° maximum).

2. Avoid hills with excessively slippery or loose surfaces.

3. Shift body weight uphill.

4. Drive straight downhill.

5. Slow down. Never go down a hill at high speed.

6. Avoid going down a hill at an angle, which can cause the vehicle to

pitch sharply to one side.

7. Squeeze the brake lever gradually. Applying the brakes too firmly

may cause the rear wheels to lock, which could result in loss of control.

OPERATION

2.4 m

Turning Around on a Hill (K-Turn)

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

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 vehi-

cle 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. Remount the vehicle from the uphill side,

keeping body weight uphill.

7. Start the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed

with the brake lever, until the vehicle is on more level ground.

OPERATION

Maximum Depth

Driving Through Water

Your Polaris vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water:

1. Determine water

depths and current before entering water.

2. Choose a crossing

where both banks have gradual inclines.

3. Avoid operating

through deep or fastflowing water.

4. After leaving water,

test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

NOTICE: Major engine damage can result if the vehicle is not thoroughly

If it’s unavoidable to enter water deeper than the footrest level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops.

Do not make sudden throttle changes.

inspected after operation in water. Perform the services outlined in the maintenance chart. See page 50. The following areas need special attention: engine oil, transmission oil, front and rear gearcases (if equipped) and all grease fittings

If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 84, then see your dealer for service at the first opportunity.

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Be alert. Watch the terrain. Use extra caution

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

7. Do not use the override switch unless additional wheel speed is

required for vehicle movement. Use the override with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Operate the throttle just enough to maintain a desired speed.

NOTICE: Excessive throttle operation while in the speed limit mode may cause

fuel to build in the exhaust, resulting in engine popping and/or engine damage.

OPERATION

Hauling Cargo

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

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.

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 only one rack increases the possibility of vehicle overturn.

CARRY LOADS 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.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

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

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level 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

1/3

2/3

Hauling Cargo

Load Distribution

Accessory racks and hitches are available from your Polaris dealer. Read and understand the load distribution warnings listed on the vehicle warning labels. Never exceed the specified weights.

Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Do not obstruct the headlight beam with cargo.

Towing Loads

Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15°.

Always attach a towed load to the hitch point. Remove the hitch from the vehicle when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight.

• The combination of rear rack cargo weight and tongue weight must

not exceed the rear rack capacity.

• The total load (operator, accessories, cargo and weight on hitch) must

not exceed the maximum weight capacity of the vehicle.

OPERATION

Parking on an Incline

Avoid parking on an incline. If it's unavoidable, follow these precautions:

1. Stop the engine.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Always block the rear wheels on the downhill side.

5. Turn the fuel valve off.

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 Canadian ICES-002. This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/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 111.

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour (16 km/h). Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

MAINTENANCE

Periodic Maintenance Chart

Improperly performing the procedures marked with a  could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services.

Maintenance Chart Key

X Perform these operations more often 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.)

Q Have an authorized Polaris dealer perform these services.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering - Pre-Ride - Make adjustments as need

X Front suspension - Pre-Ride - X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride - X Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride - XEAir filter, pre-filter - Daily - Inspect; clean often; replace

X Air box sediment

tube

Coolant - Daily - Check level daily; change

Headlamp/tail lamp

XEAir filter,

main element

Brake pad wear 10 Monthly 100 (160) Inspect periodically

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

X Front gearcase oil

(if equipped)

X Transmission oil 25 Monthly 250 (400) Inspect level; change yearly XEEngine breather

filter (if equipped)

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Kilometers

ed. See Pre-Ride Checklist on page 33.

as needed

- Daily - Drain deposits when visible

coolant every 2 years

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

25 Monthly 250 (400) Inspect level; change yearly

25 Monthly 250 (400) Inspect; clean if needed

dielectric grease if replacing

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

XEEngine oil change

(break-in)

X General

lubrication

Carburetor float bowl

Throttle Cable/

ETC Switch

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

E Carburetor air

intake ducts/flange

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

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

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

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

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

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

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

X Radiator 100 12 M 1000 (1600) Inspect; clean external

X Cooling hoses

(if applicable)

X Engine mounts 100 12 M 1000 (1600) Inspect

(whichever comes first)

Hours Calendar Miles

25 1 M 250 (400) Perform a break-in oil change

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

50 6 M 500 (800) Drain bowl periodically and

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

50 6 M 500 (800) Inspect duct for proper seal-

100 12 M 1000 (1600) Inspect for leaks

(Km)

cables, etc.

prior to storage

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at 20 hours

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

surfaces

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

Exhaust muffler/ pipe

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

Ignition Timing 100 12 M 1000 (1600) Inspect

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

Clutches (drive and driven)

Front wheel bearings

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

Spark arrestor 300 36 M 3000 (4800) Clean out

E Idle speed - Adjust as needed

Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

100 12 M 1000 (1600) Inspect

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

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

(Km)

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

parts

when parts are replaced

Remarks

MAINTENANCE

Swing Arm

Bushings

Tie Rod

Ends

Axle

Housing

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Items not listed in the chart should be lubricated at the General Lubrication interval.

Item Lube Method

Engine Oil PS-4 PLUS Performance

Brake Fluid DOT 4 Only See page 63.

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

Transmission Oil Polaris AGL Synthetic

Swing Arm Bushings XPremium All Season

Axle Housing Tie Rod Ends XPremium All Season

Synthetic 2W-50

80/90

Gearcase Lube

Grease

See page 56.

Lubricate.

See page 60.

Locate fittings on swing arm and grease with grease gun

Lift boot, clean away dirt and grease, apply fresh grease by hand and reassemble. Perform when suspension action becomes stiff, or after washing.

MAINTENANCE

Safe

Add Oil

{

Safe Range

Engine 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.

NOTICE: Mixing brands or using a non-recommended oil may cause serious

Oil Specifications

PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil

Oil Level

The oil dipstick is located on the left side of the vehicle.

1. Position the vehicle on a level

2. Start the engine. Allow it to idle

3. Remove the dipstick. Wipe it dry

4. Reinstall the dipstick completely.

5. Remove the dipstick and check

6. Reinstall the dipstick.

engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Lubricant Capacity Drain Plug Torque

2 qts. (1.9 l) 14-17 ft. lbs. (19-23 Nm)

surface. Place the transmission in neutral. Lock the parking brake.

for 30 seconds. Stop the engine.

with a clean cloth.

Make sure the cap is fully seated to keep the angle and depth of the stick consistent.

the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill.

MAINTENANCE

Screen Fitting

Sealing Washer

Drain Plug

Mark

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface. Clean the area around the

drain plug at the bottom of the oil tank and the bottom of the engine.

2. Start the engine. Allow it to idle for two to three minutes. Stop the

engine.

3. Place a drain pan under the oil tank. Remove the drain plug. Allow

the oil to drain completely.

CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

4. Reinstall the drain plug with

a new sealing washer. Torque to specification. See page 56.

Tip: The sealing surfaces on the

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

5. Disconnect the lower oil

delivery hose and remove the screen fitting from the oil tank. Clean the fitting.

NOTICE: The fitting threads must

6. Reinstall the screen fitting

NOTICE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft.

7. Reattach the oil line.

be sealed with LOCTITE PST 505 or PTFE seal tape.

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 on the tank.

lbs. (34 Nm).

MAINTENANCE

Filter

Oil and Filter Change

8. Place towels under the oil filter.

Using an oil filter wrench, turn the filter counterclockwise to remove it.

9. Lubricate the gasket on the new

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

10. Install the new oil filter. After

the filter contacts the engine surface, turn it 1/2 to 3/4 turn by hand.

11. Approximately one cup of engine oil will remain in the crankcase.

To drain, remove the drain plug on the lower right side of the crankcase.

Tip: The sealing surfaces on the drain plug and crankcase should be clean and

free of burrs, nicks or scratches.

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

13. Remove the dipstick. Add the recommended oil. See page 56. Rein-

stall the dipstick.

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

14. Place the transmission in neutral. Lock the parking brake.

15. Prime the oil pump using the procedure on page 59. Then stop the

engine and inspect for leaks.

16. Remove the dipstick and check the oil level. Add oil as needed.

Maintain the oil level in the safe range. Do not overfill.

17. Discard used oil and filter properly.

Oil and Filter Change

Relief

Slit

2” (5 cm)

Vent Line

Oil

Ta n k

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 approximately two inches (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

2. Run the engine for 10-20

seconds.

3. Remove the vent line

clamp. If the line is bled properly, you should hear a rush of air, indicating that the line is properly primed and ready for operation. If

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

MAINTENANCE

Safe

Range

Transmission Oil

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Maintain the oil level within the SAFE operating range on the dipstick.

Transmission Oil Recommendations

Gearcase Lubricant Capacity Drain Plug Torque

Transmission Premium AGL Synthetic

Gearcase Lubricant

Oil Check

1. Position the vehicle on a level surface.

2. The transmission oil dipstick is located on the right side of the vehi-

cle. 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.

5. Reinstall the dipstick.

11.3 oz. (334 ml)

14 ft. lbs.

(19 Nm)

MAINTENANCE

Jam

Nut

Drain Plug

Adjuster

Bolt

Transmission Oil

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.

4. Turn the adjuster bolt in to allow

the removal of the drain plug.

5. Remove the drain plug and wipe

the magnetic end clean to remove accumulated metallic filings.

6. After the oil has drained com-

pletely, install a new sealing washer and reinstall the drain plug. Torque to specification.

7. Turn the adjuster bolt 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. Discard used oil properly.

MAINTENANCE

Brakes

Brake Fluid

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

Once open, a bottle of brake fluid absorbs moisture from the air, which causes the boiling temperature of the brake fluid to drop. This can lead to early brake fade and the possibility of accident. Do not store opened brake fluid. Properly discard any unused portion.

Always maintain brake fluid at the recommended level. Do not overfill. If the fluid level is low add DOT 4 brake fluid only. See page 104 for the part numbers of Polaris products.

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

MAINTENANCE

Master Cylinder

Indicator

Window

Add

Full

Brakes

Brake Fluid (Hand Brake)

Check the brake fluid level in the master cylinder before each use of the vehicle. The master cylinder is located on the left handlebar. Maintain the fluid level 1/4" (6 mm) below the top edge of the master cylinder. Do not overfill.

1. Position the vehicle on a level

surface. Make sure the handlebars are straight.

2. View the fluid level through

the indicator window (eye) on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.

3. Add the recommended fluid as needed. Do not overfill.

Brake Fluid (Auxiliary Foot Brake)

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 maximum and minimum marks.

The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.

MAINTENANCE

1 mm

Brakes

Brake Check

Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily during normal operation.

1. Always keep foot brake fluid at an

adequate level. Check the foot brake system regularly for fluid leaks.

2. Check the brakes for excessive

travel or spongy feel.

3. Check the brake pads for wear, dam-

age or looseness. Replace pads when they are worn to 1 mm.

4. Check the security and surface condition of the brake discs.

MAINTENANCE

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out.

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.

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 25 cm from the floor, or as close to the hub/axle center line as possible. Make sure both marks are the same distance from the floor.

4. Measure the distance

between the marks and record the measurement (1).

5. Move the vehicle until the

chalk marks are at the rear of the tires, even with the hub/axle center line.

6. Measure the distance between the marks and record the

measurement (2).

7. Subtract measurement 2 from measurement 1. The difference is the

vehicle toe-out alignment.

8. If you discover improper alignment, see your Polaris dealer for ser-

vice.

MAINTENANCE

Jam

Nut

Adjusting

Ring

Clicker

Steering Assembly

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

Rear Suspension

The rear suspension spring preload and shock compression damping may be adjusted to suit different riding conditions and operator weight.

Spring Preload

1. Raise and safely support the rear of

the vehicle off the ground to allow the suspension to fully extend.

2. Loosen the jam nut and back it

away from the adjusting ring.

3. Turn the adjusting ring counter-

clockwise (1) to increase preload. Turn the ring clockwise (2) to decrease preload.

4. Tighten the jam nut firmly against

the adjuster ring.

Compression Damping

Use a flat-blade screwdriver to make damping adjustments. The factory setting is at 10 clicks from fully closed.

The compression damping clicker is located on the end of the shock reservoir.

1. Turn the clicker clockwise (1) to

increase compression damping.

2. Turn the clicker counter-clockwise

(2) to decrease compression damping.

MAINTENANCE

1.6-3 mm

Lock Nut

Sleeve

Boot

Throttle Cable Freeplay

Adjust throttle cable freeplay at the handlebar.

1. Slide the boots off the inline cable

adjuster sleeve. Loosen the adjuster locknut.

2. Turn the adjuster until 1.6-3 mm of

freeplay exists at the lever. Move the throttle lever back and forth several times while adjusting.

3. Tighten the lock nut and slide the

boots over the cable adjuster until they touch at the midpoint of the adjuster.

Tip: Engine RPM should not increase when steering is turned full left or right.

Readjust cable freeplay if this occurs.

MAINTENANCE

Handlebar Bolts

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 serious 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.

2. Loosen (do not remove) the four

handlebar clamp bolts.

3. Adjust the handlebar to the

desired height.

4. Be sure the handlebars do not

contact the gas tank or any other part of the machine when turned fully to the left or right.

5. Torque the front two bolts to 14-17 Nm, then torque the rear two

bolts.

Tip: A gap of up to 3 mm should remain at the rear bolts.

MAINTENANCE

Idle

Adjuster

Carburetor

Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher. Above 1800 meters the engine air/fuel mixture becomes too rich and the engine loses approximately 3% of its power for each 300 meter increase in elevation. Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient operation. Optional jets and clutch components, available from your Polaris dealer, are required for operation above 1800 meters and at temperatures below 4 degrees C.

Tip: Continuous operation of the engine without proper jetting when required

can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting.

Carburetor/Engine Idle RPM Adjustment

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

1. Position the vehicle on a level sur-

face. Place the transmission in gear. Lock the parking brake.

2. Start the engine. Allow it to idle for

approximately five minutes. Stop the engine.

3. Turn the carburetor idle screw in

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

MAINTENANCE

Drive Chain

Drive Chain Lubrication

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 mm).

Regularly lubricate the drive chain with Polaris Chain Lube, an SAE 8090 lube or an approved o-ring chain spray lube. See page 104 for the part numbers of Polaris products.

NOTICE: 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

3/16"-3/8" (5 mm - 10 mm)

Locking Bolts

Pin Punch

Drive Chain

Rear Drive Chain Slack

Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three positions. At this point the chain should have 3/16"-3/8" (5 mm - 10 mm) deflection.

NOTICE: Adjusting or operating the vehicle with improper rear drive chain

Use the following procedure if adjustment is required.

1. Remove the chain guard.

2. Loosen the chain guide.

3. Loosen the two eccentric

4. Loosen the caliper mounting

5. Insert a pin punch through

slack can result in severe damage to the transmission and drive components. Always make sure the slack is within the stated specifications.

locking bolts.

bolt located on the left side of the swing arm.

the sprocket hub and into the eccentric housing.

MAINTENANCE

Clip

Position

Drive Chain

Rear Drive Chain Slack

6. Roll the vehicle forward or back-

ward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position.

7. Tighten the eccentric locking bolts

to 30 ft. 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.

Tip: The chain is adjusted correctly when the tightest portion of the chain has

approximately 3/8" (10mm) deflection.

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

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

12. Reinstall the chain guard.

MAINTENANCE

Recovery Bottle

Cooling System

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

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

Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Check the coolant level and maintain as recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 104 for the part numbers of Polaris products.

Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

Recovery Bottle Coolant

The recovery bottle is located on the left side of the vehicle.

1. Maintain the coolant level

between the minimum and maximum marks on the bottle (when the fluid is cool).

2. Add coolant as needed.

MAINTENANCE

Radiator Cap

Cooling System

Radiator Coolant

To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for maintenance or repair. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed.

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

1. Remove the front panel to

access the radiator pressure cap.

2. Remove the pressure cap.

3. If coolant is low, use a fun-

nel and slowly add coolant through the radiator filler neck.

4. Reinstall the pressure cap.

Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.

5. Secure the front panel.

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

7. Check the coolant level in the bottle frequently, adding coolant as

needed until the level stabilizes.

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility.

Headlamp Replacement

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.

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

CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing.

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

bulb.

3. Apply dielectric grease to the light bulb socket before installing the

new bulb. Install the replacement bulb into the headlight housing and rotate clockwise firmly.

Tip: The bulb must be positioned so the harness installs into the lamp at the bot-

tom.

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

MAINTENANCE

Lamp

Lights

Taillight/Brakelight Lamp Replacement

1. Remove the taillight lens cover

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

2. Remove the lamp.

3. Apply dielectric grease to the

socket and install the new lamp.

4. Test the taillight/brake light for

proper operation.

5. Reinstall the gasket and lens cover.

Indicator Lamp Replacement

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

indicator panel.

2. Using a small, straight-blade screwdriver, turn the base of the bulb

1/4 turn counterclockwise.

3. Using a needle-nose pliers 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

WARNING

3 mm

Tires

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. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 102 for recommended tire type, size and pressure.

Wheel and Hub Tightening

Wheel hub and bearing tightness and spindle nut retention are critical items. These services must be performed by an authorized dealer.

Tire Tread Depth

Always replace tires when tread depth is worn to 3 mm or less.

MAINTENANCE

Tires

Wheel Removal

1. Position the vehicle on a level surface. Place the transmission in

gear. Lock the parking brake.

2. Loosen the wheel nuts slightly.

3. Safely place jackstands under the

vehicle.

4. Remove the wheel nuts. Remove

the wheel.

Wheel Installation

1. Place the wheel on the wheel hub

with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation.

2. Install the wheel nuts finger tight.

On vehicles with tapered rear wheel nuts, make sure the tapered ends of the nuts fit into the tapers on the wheels.

3. Lower the vehicle to the ground.

4. Torque the wheel nuts to

specification (page 79).

WARNING! Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn. Always ensure that all nuts are torqued to specification.

MAINTENANCE

Rear

50 ft. lbs.

(68 Nm)

Front

27 ft. lbs.

(37 Nm)

Tires

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loosened for service.

Item Torque Specification

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

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

MAINTENANCE

Pre-Filter

Main Filter

Air Filter

1. Position the vehicle on a level surface. Place the transmission in

gear. Lock the parking brake.

2. Remove the seat.

3. Release the air box cover

clips, and remove the air box cover.

4. Loosen the clamp and

remove the filter.

5. Remove the pre-filter

from the main filter.

6. Wash the pre-filter in

soapy water, then rinse and let dry.

7. Reinstall the pre-filter

over the main filter. Replace the main filter if needed.

8. Reinstall the air filter into the air box. Tighten the clamp, but do not

over-tighten as filter damage could occur.

9. Reinstall the air box cover and the seat.

MAINTENANCE

Breather Filter

1. Remove the clamps and pull the

breather filter out of the hoses. It's not necessary to remove the lower hose from the engine.

2. Inspect the filter for debris.

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

3. Check the hoses for cracks,

deterioration, abrasion, or leaks. Replace as needed.

4. Reinstall the filter and secure the clamps. The filter is effective with

the arrow pointing in either direction.

NOTICE: Operation of your vehicle without a breather filter can cause engine

damage. Always reinstall the breather filter after removing it for service.

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 102 for the recommended spark plug type and gap for your vehicle.

NOTICE: Using non-recommended spark plugs can result in serious engine

Spark Plug Inspection

Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 83.

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

1. Remove the spark plug cap.

2. Using the special wrench pro-

3. Inspect the electrodes for wear

4. Reverse the procedure for spark plug installation. Torque to

damage. Always use Polaris-recommended spark plugs.

Plug Condition Torque Specification

New Spark Plug 12-15 Nm

Previously Installed Spark Plug 23-27 Nm

vided in the tool pouch, rotate the spark plug counterclockwise to remove it.

and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation.

specification.

MAINTENANCE

Spark Plugs

Spark Plug Condition

Normal Spark Plug

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

The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

Wet Fouled Spark Plug

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

MAINTENANCE

Drain Screw

Vehicle Immersion

If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

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

1. Move the vehicle out of the water.

2. Turn the fuel valve off.

3. Check the air box. If water is present, dry the air box and replace the

filter with a new filter.

4. Remove the spark plug.

5. Loosen the carburetor drain screw

and drain the carburetor.

6. Turn the engine over several times

using the electric start.

7. Dry the spark plug. Reinstall the plug

or install a new plug.

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

10. Attempt to start the engine. If neces-

sary, repeat the drying procedure.

11. Have the vehicle serviced by your

dealer promptly, whether you succeed in starting it or not.

12. If water has been ingested into the transmission, follow the proce-

dure on page 88 for drying.

MAINTENANCE

WARNING

Exhaust

Outlet

Clean-Out Plug

Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined.

The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler.

1. Position the vehicle on a

level surface.

2. Place the transmission in

neutral.

3. Lock the parking brake.

4. Remove the arrestor clean-

out plug from the bottom of the muffler.

5. Start the engine.

6. Quickly squeeze and release the throttle lever several times to purge

carbon from the system.

7. If carbon comes out of the exhaust, cover or plug the exhaust outlet.

Wear protective gloves.

8. Lightly tap on the exhaust pipe with a rubber mallet while repeating

step 6.

9. If particles are still suspected to be in the muffler, elevate the rear of

the vehicle one foot (30 cm) higher than the front. Block the wheels.

10. Place the transmission in neutral. Lock the parking brake. Repeat

steps 6 to 8 until no more particles are expelled.

11. Stop the engine. Allow the arrestor to cool.

12. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

MAINTENANCE

WARNING

PVT System

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.

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 (8 km/h), due to the system's dependence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 km/h), the engine would be running at only about 1500 RPM, with an engagement speed of about 1400 RPM. Whenever operating this close to the engagement speed, the engine may be running at a speed too low to provide the pinch needed to prevent belt slip. Belt slip is responsible for creating the excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail.

If the vehicle will be operated for extended periods below 5 MPH (8 km/h), or for towing loads, we recommend that you install a one tooth smaller counter shaft sprocket to raise the operating RPM far enough above the engagement RPM to reduce heat caused by incomplete engagement. Reducing the temperature inside the clutch cover greatly extends the life of the PVT components (belt, cover, etc.).

Tip: Avoid heavy pulling and extended low-speed operation.

MAINTENANCE

PVT System

PVT Drying

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

1. Move the vehicle out of the water.

2. Remove the PVT drain plug. Allow the water to drain completely.

Reinstall the drain plug.

3. Start the engine. Place the transmission in neutral.

4. 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.

5. Allow the engine RPM to settle to idle speed, then shift the trans-

mission into forward gear.

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

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

MAINTENANCE

WARNING

Battery

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 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.

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.

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.

MAINTENANCE

Battery

Battery Removal

1. Place the transmission in gear.

2. Lock the parking brake.

3. Disconnect the battery hold-down strap.

4. Remove the battery cover.

5. On conventional batteries, remove the battery vent tube.

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

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

8. Lift the battery out of the vehicle. Be careful not to tip a conven-

tional battery sideways, which could spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the vehicle.

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 page 93 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed bat-

teries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

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. Cables should be safely

tucked away at the front and rear of the battery.

MAINTENANCE

Lower

Mark

Upper

Mark

Battery

Battery Storage

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

Tip: Power plug leads may need to be bent down so that the battery cover can

be installed.

Polaris recommends maintaining battery charge by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See page 104 for the part numbers of Polaris products.

Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks.

Add only distilled water. Tap water contains minerals that are harmful to a battery.

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 90.

2. Charge the battery with a charging output no larger than 1/10 of the

battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. See page 91. Make sure the positive terminal is

toward the front of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.

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

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps

or less until battery voltage is 12.8 or greater.

3. When using an automatic charger, refer to the charger manufac-

turer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging.

MAINTENANCE

Battery

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of charging.

State of

Charge

100% 12.8-13.0 volts None, check at 3

75%-100% 12.5-12.8 volts May need slight

50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.0 volts Needs charge At least 13 hours,

0%-25% 11.5 volts or less Needs charge with

Voltage Action

mos. from date of

manufacture

charge, if no

charge given,

check in 3 months

desulfating charger

Charge Time

(Using constant current

charger @ standard amps

specified on top of battery)

None required

3-6 hours

verify state of charge

At least 20 hours

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping the vehicle clean will extend the life of components.

NOTICE: High water pressure may damage components. Polaris recommends

The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the finish.

washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will

damage plastic surfaces. Do not allow these types of products to contact the vehicle.

and the lower parts last.

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components. Avoid directing the water stream at the following items:

• Wheel bearings • Electrical components/wiring

• Radiator • Switches and controls

• Transmission seals • Cab and body panels

• Brakes • Labels and decals

If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge.

Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

Polishing the Vehicle

Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

MAINTENANCE

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use

abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive

grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol-

ished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as outlined above.

MAINTENANCE

Cleaning and Storage

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 95.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to

4. Stop the engine.

5. Turn the fuel valve off.

6. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 57.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter.

2. Clean the air box.

3. Clean or replace the breather filter.

4. Drain the sediment tube.

protective film created by fogging and damage could occur. Never start the engine during the storage period.

Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

disperse through the fuel in the tank and carburetor.

Polaris Scrambler 9922077, Scrambler 500 2X4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual