Polaris 2008 Scrambler 500 4X4 Owner'S Manual Download

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Summary of Contents for 2008 Scrambler 500 4X4

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Page 3: ...r s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance The engine exhaust from this product contains chemicals known to the Stat...

Page 4: ...For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information...

Page 5: ...nor 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 liabil...

Page 6: ...ICLE IDENTIFICATION NUMBERS 5 SAFETY 6 FEATURES AND CONTROLS 31 OPERATION 43 EMISSION CONTROL SYSTEMS 61 MAINTENANCE 62 SPECIFICATIONS 110 POLARIS PRODUCTS 113 TROUBLESHOOTING 114 WARRANTY 118 MAINTEN...

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Page 8: ...d store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replace...

Page 9: ...ining ATV safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible family members...

Page 10: ...your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safe...

Page 11: ...street road or highway including a dirt or gravel road S Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a lo...

Page 12: ...attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use prope...

Page 13: ...FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 Equipment Modifica...

Page 14: ...e and the operating techniques described in the Owner s Manual For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org WARNING POTENT...

Page 15: ...allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking...

Page 16: ...POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe...

Page 17: ...fore or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZA...

Page 18: ...r stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility o...

Page 19: ...into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POT...

Page 20: ...e on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain...

Page 21: ...per hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain careful...

Page 22: ...res for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 55 Always check the terrain carefully before descend...

Page 23: ...t to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 56 Use extra caution when turning on any hill Avoid crossin...

Page 24: ...en fully stopped apply the auxiliary rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the auxiliary rear brake...

Page 25: ...nual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD...

Page 26: ...nts and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after le...

Page 27: ...re information WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of...

Page 28: ...ng systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased ri...

Page 29: ...o not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run i...

Page 30: ...than 25 degrees 25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually S REVERSE operation can be dangerous even at low speeds Steering becomes difficult To p...

Page 31: ...R 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...

Page 32: ...rol resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY 305 LBS 138 KG Reduce speed and allow greater distance for braking when carrying cargo...

Page 33: ...ich has granted approval The approval number and serial number will also be displayed on the label 2 Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a Polar...

Page 34: ...turn the main key switch clockwise past the ON position Release the key when the engine starts NOTE Turn off the main switch to end all electrical power to the vehicle including the lights WARNING Le...

Page 35: ...light switch is located on the left handlebar 1 It s used to turn the lights on and off and to switch the lights from high beam to low beam NOTE The lights won t work unless the key is in the ON posit...

Page 36: ...ring operation Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded Engine speed returns to idle when the lever is released This ATV is...

Page 37: ...ezing the brake lever 1 toward the handlebar The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylin...

Page 38: ...us injury or death Maintain brake fluid at the recommended level Do not overfill NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is l...

Page 39: ...1 forward to engage the brake Release the brake lever 3 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards S The parking...

Page 40: ...erious injury or death The auxiliary foot brake 1 is located on the inside of the right floorboard and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if...

Page 41: ...TE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return the valve to the ON position after refuel...

Page 42: ...rd N Neutral R Reverse CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idlin...

Page 43: ...in the ON position NOTE If the engine is cold use the choke as outlined on page 45 4 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other s...

Page 44: ...There is no limit to the length of time the vehicle may remain in AWD Engaging Wheel Hubs The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system w...

Page 45: ...d vehicle speed is somewhat restricted Disengage the hubs by stopping shifting to reverse and backing for a short distance Then proceed in forward again NOTE If the hubs remain engaged after following...

Page 46: ...vel on the dipstick see page 68 Add the recommended oil as needed to maintain the oil level in the normal operating range 1 3 Drive slowly at first Select an open area that allows room to familiarize...

Page 47: ...Wheels fasteners Inspect ensure fastener tightness 82 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 68 Coolant level if applicable Ensure proper level 86 Coola...

Page 48: ...the vehicle NOTE Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled 6 If the engine is cold pull the choke knob out until it stops...

Page 49: ...art intermittent use of the choke button pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the thro...

Page 50: ...to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin...

Page 51: ...tion warnings on all warning labels and never exceed the specified weight capacities for the vehicle Maximum Towing Capacities Refer to the specifications at the rear of this manual for towing capacit...

Page 52: ...LOADS MUST BE SECURED BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOAD...

Page 53: ...tion of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the...

Page 54: ...andlebars in the direction of the skid and shifting your body weight forward 4 Driving with AWD engaged can assist in controlling the vehicle in slippery areas CAUTION Severe damage to the drive train...

Page 55: ...dehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into t...

Page 56: ...when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25_ maximum Use extreme caution when operati...

Page 57: ...forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary brake as well then lock the park brake If the ATV begins rolling backwards...

Page 58: ...vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing using the single brake lever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the...

Page 59: ...vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll a...

Page 60: ...ear gearcases if equipped and all grease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the mainte...

Page 61: ...the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obs...

Page 62: ...s or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines...

Page 63: ...parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 1 Place the transmission in gear 2 Set the parking brake 3 Always block the rear wheels on the dow...

Page 64: ...gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit th...

Page 65: ...ce 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 appr...

Page 66: ...val whichever comes first Remarks Hours Calendar Miles Km J Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist Front suspension Pre Ride j ed See Pre Ride Checklist on page 44 Rear s...

Page 67: ...nspect adjust lubricate replace if necessary J E Choke cable 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50 H 6 M 500 800 Inspect ducts for prop...

Page 68: ...r wear routing security apply dielectric grease to connectors subjected to water mud etc J Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts J Front wheel bearings 100 H...

Page 69: ...submerging When suspension action becomes stiff or after washing Item Lube Method Engine Oil PS 4 PLUS Performance Synthetic 2W 50 Add to proper level on dipstick Brake Fluid DOT 4 fluid only Maintai...

Page 70: ...67 MAINTENANCE Lubrication Recommendations 1 3 2 7 6 4 5 4 or 8 o clock position end view 8...

Page 71: ...e 113 for the part numbers of Polaris products CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oi...

Page 72: ...drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain plug and torque to 14 17 ft lbs 19 23 Nm 6 Disconnec...

Page 73: ...drain remove the drain plug on the lower right side of the crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 13 Reinstall the dr...

Page 74: ...line 1 approximately 2I from the oil tank 2 between the end of the oil tank vent fitting and the vent line s pressure relief slit 3 2 Run the engine for 10 20 seconds 3 Remove the vent line clamp If...

Page 75: ...d the recommended lubricant as needed 4 Reinstall the fill plug Torque to 14 ft lbs 19 Nm 5 Reinstall the propshaft shield Oil Change 1 Position the ATV on a level surface 1 Remove the propshaft shiel...

Page 76: ...osition the ATV on a level surface 2 Remove the fill plug 1 and check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to 14 ft lbs 19 Nm Oil Change 1 Position the AT...

Page 77: ...Also check for correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 cm Regularly lubricate the drive chain with Polaris Chain Lube an SAE 80 90 lube or an approved o...

Page 78: ...nd secure them in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible Make sure both ma...

Page 79: ...drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always maintain brake fluid at an ad...

Page 80: ...hould be changed when worn to 3 64 1 cm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activa...

Page 81: ...se or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handle...

Page 82: ...dures exactly or see your Polaris dealer for service The handlebars can be adjusted for rider preference 1 Remove the handlebar cover to access the handlebar bolts 1 2 Loosen the four bolts 3 Adjust t...

Page 83: ...and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating and engine or PVT damage See your P...

Page 84: ...the decal on your ATV and in your owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth...

Page 85: ...the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten On vehicles with tapered rear wheel n...

Page 86: ...vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less W...

Page 87: ...e slightly forward to gain slack at the top side of the rear chain Measure the chain slack at the tightest of the three positions At this point the chain should have 3 16 3 8 48 cm 95 cm deflection Us...

Page 88: ...ut 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 ATV forward checking chain tension in several places a...

Page 89: ...ck up from the tank past the pressure cap and into the radiator Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as...

Page 90: ...diator should be inspected and coolant added if necessary 1 Remove the front panel to access the radiator pressure cap 1 Remove the cap 2 If coolant is low use a funnel and slowly add coolant through...

Page 91: ...et before installing the new bulb Install the replacement bulb into headlight housing and rotate clockwise firmly NOTE The bulb must be positioned so the harness installs into the lamp at the bottom 4...

Page 92: ...the new lamp 4 Test the taillight brakelight for proper operation 5 Reinstall the gasket and lens cover Indicator Lamp Replacement 1 Remove the instrument panel if necessary to access the back of the...

Page 93: ...lter damage could occur Breather Filter Hose CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service 1 Remov...

Page 94: ...Previously Installed Spark Plug 17 20 ft lbs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been w...

Page 95: ...y the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Recoil Housing To prevent...

Page 96: ...r any water Drain and dry it if water is present 3 Turn the fuel valve off 4 Remove the spark plug 5 Turn the engine over several times using the electric start 6 Loosen the carburetor drain screw 1 7...

Page 97: ...t only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engagement point the engine may be running at a speed too low to provide the adequate pinch needed...

Page 98: ...tenance 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 housin...

Page 99: ...hicle while it s inclined 1 Remove the arrestor clean out plug 1 from the bottom of the muffler 2 Place the transmission in neutral and start the engine 3 Purge carbon from the system by momentarily r...

Page 100: ...clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING Battery electrolyte is poison...

Page 101: ...Disconnect the hold down strap holding the battery in position and remove battery cover 2 On conventional batteries remove the battery vent tube 3 Disconnect the black negative battery cable first 4 D...

Page 102: ...curely 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 explos...

Page 103: ...as needed to maintain a full charge NOTE Power plug leads may need to be bent down so that the battery cover can be installed NOTE Battery charge can be maintained by using a Polaris Battery Tender ch...

Page 104: ...nerals that are harmful to a battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging See page 98 2 Cha...

Page 105: ...and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery could explode causing severe injury or death Always watch charging ti...

Page 106: ...ent charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given ch...

Page 107: ...of products to come into contact with the vehicle 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...

Page 108: ...ed contact your Polaris dealer for free replacement 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 ex...

Page 109: ...nt 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 periodi...

Page 110: ...tment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from...

Page 111: ...ml of engine oil into the hole NOTE Use a section of small hose and a small plastic squeeze bottle filled with the pre measured amount of oil 4 Reinstall the spark plug Torque to specification 5 Appl...

Page 112: ...ed Cover the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Trans...

Page 113: ...l 2 qts 1 89 l Turn Radius 83 in 210 8 cm Ground Clearance 5 5 in 14 cm Height 47 in 119 4 cm Length 75 in 190 5 cm Width 46 in 116 8 cm Seat Height 34 in 86 4 cm Wheel Base 48 in 121 9 cm Engine Cool...

Page 114: ...26 7 cm travel Shock Adjustment CAM Front Brake Fixed disc hydraulic floating caliper Rear Brake Fixed disc hydraulic floating caliper Auxiliary Brake Fixed disc hydraulic floating caliper Park Brake...

Page 115: ...ters Feet 0 1800 0 6000 160 155 1800 3700 6000 12000 152 5 147 5 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Spring Setting Meters Feet 0 1800 0 6000 10WH 5630...

Page 116: ...m Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cart...

Page 117: ...ng Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of cont...

Page 118: ...is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify...

Page 119: ...e ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel vent line Inspect and repla...

Page 120: ...s See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to...

Page 121: ...MEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improp...

Page 122: ...ESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform war ranty service Please work with your dealer to resolve any warra...

Page 123: ...ized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer wi...

Page 124: ...r replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL...

Page 125: ...122 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 126: ...123 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 127: ...124...

Page 128: ...rain Break in 43 Driving Downhill 55 Driving in Reverse 59 Driving on Slippery Surfaces 51 Driving Over Obstacles 58 Driving Procedures 47 Driving Safely 47 60 Driving Through Water 57 Driving Uphill...

Page 129: ...ing 92 Recoil Starter 40 S Safe Riding Gear 30 Safety Decals and Locations 27 29 Safety Training 6 Sidehilling 52 Spark Arrestor 96 Spark Plugs 91 92 Specifications 110 112 Starting the Engine 45 46 S...

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Polaris 2008 Scrambler 500 4X4, Owner'S Manual

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