Polaris 2010 Scrambler 4X4 Owner'S Manual Download

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MAINTENANCE

Handlebars

The handlebars can be adjusted for rider preference.

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.

1. Remove the handlebar cover to

access the handlebar bolts.

2. Loosen the four handlebar 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 10-12 ft. lbs. (14-17 Nm), then torque

the rear two bolts. A gap of up to 1/8" (3 mm) will remain at the rear

bolts.

Handlebar Bolts

Summary of Contents for 2010 Scrambler 4X4

Page 1: ......

Page 2: ...er 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 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW ...

Page 4: ... 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 ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL For your nearest Polaris dealer call 1 800 POLARIS o...

Page 5: ...r safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your Polaris dealer knows your vehicle best and is i...

Page 6: ... and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation 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 i...

Page 7: ...tion 4 Safety 7 Features and Controls 26 Operation 37 Emission Control Systems 56 Maintenance 57 Polaris Products 109 Troubleshooting 110 Specifications 114 Declaration of Conformity 116 Warranty 117 Maintenance Log 125 Index 127 ...

Page 8: ...al 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 ...

Page 9: ...r driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Neve...

Page 10: ...your key number and mating it with one of your existing keys 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 ________________...

Page 11: ...TV RiderCoursesm for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a Polaris ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We s...

Page 12: ...eeds 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 l...

Page 13: ...o protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your Polaris ATV is terminated if any equipment ...

Page 14: ... properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE O...

Page 15: ...ve off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated are...

Page 16: ...its properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV Carrying a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which may result ...

Page 17: ... sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increa...

Page 18: ...ing improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or ove...

Page 19: ...g a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides 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 ...

Page 20: ... in the owner s manual See page 49 If the ATV begins rolling downhill Keep body weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and r...

Page 21: ...h slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terra...

Page 22: ...2 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always maintain proper tire pressure as described in the owner s ma...

Page 23: ...ra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 50...

Page 24: ...cargo or pull ing a trailer Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident especially if operating on a road or street This ATV is...

Page 25: ...l disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry gra...

Page 26: ... 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 passenge...

Page 27: ...er 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 General Warning Discretionary Warning ...

Page 28: ...r DEATH 7175378 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 4 0 psi 27 6 kPa Rear 3 0 psi 20 7 kPa Maximum weight capacity 275 lbs 125 kg 7175443 No Passenger Warning Clutch Cover Warning Age 16 Warning Tire Pressure Load Warning ...

Page 29: ...d 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 71...

Page 30: ...ride 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 Swi...

Page 31: ...o operate the headlights All Wheel Drive Switch See page 36 for all wheel drive information 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 Neutral Indicator Reverse Indicator High Temperature Warning displays if engine overheats ...

Page 32: ...ic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle control Engine speed and vehicle move ment are controlled by pressing the throttle lever The throttle l...

Page 33: ...e 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 be...

Page 34: ... unlocked position WARNING Operating the ATV 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 ATV if leaving it parked on a hill Another option i...

Page 35: ...rear wheels may skid and slide sideways causing loss of control which may result in serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake sys tem Should the main system fail use the auxiliary foot brake 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 usi...

Page 36: ...sibility of brake failure which could result in an accident After opening a bottle of brake fluid always 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 109 for the part numbers of Polaris products Under normal operation the diaphragm extends into the reservoir as fluid level drops If the ...

Page 37: ...bars 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 Auxiliary Foot Brake Check the brake fluid level frequently for the auxiliary brake system The brake fluid reservoir is located either under the...

Page 38: ... fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as 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 Fuel Filter The in line fuel filter should be replaced by your...

Page 39: ...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 speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake Gear Selector ...

Page 40: ...f AWD in reverse if the AWD switch is on Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear whe...

Page 41: ...t three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 34 Always exercise extreme caution whenever handling gasoline 2 Check the oil level on the dipstick See page 64 Add oil if neces sary to maintain the level in the safe operating range 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handlin...

Page 42: ...ed visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly 8 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 handle bars while operating and always keep both feet on the footrests 9 Never consume alcohol or d...

Page 43: ...hicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to onc...

Page 44: ...pressure 75 Wheels fasteners Inspect ensure fastener tightness 75 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 34 64 Coolant level Ensure proper level 84 Coolant hoses Inspect for leaks Throttle Ensure proper operation 28 73 Indicator lights switches Ensure operation 26 Engine stop switch Ensure proper operation 26 Drive chain Check condition slack lubricat...

Page 45: ... 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 ten sion 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 depend ing on how much choke is needed fo...

Page 46: ...ive seconds if necessary Repeat this procedure until the engine starts Tip If a warm engine has cooled to a point where it does not readily start inter 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 engin...

Page 47: ...on the handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress the throttle with your right thumb and begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 48: ...er in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turnin...

Page 49: ...se traction NOTICE Severe damage to drive train may occur if AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handleb...

Page 50: ... hills 25 maximum 3 Always check the terrain carefully before ascending any hill 4 Never climb hills with excessively slippery or loose surfaces 5 Keep both feet on the footrests 6 Shift body weight uphill 7 Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Remain alert and be prepared to take emergency action This may...

Page 51: ...ossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Shift body weight uphill 4 Keep your feet on the footrests 5 If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately ...

Page 52: ...ls 25 maximum 2 Shift body weight uphill 3 Drive straight downhill 4 Slow down Excessive speed when traveling downhill can cause loss of control 5 Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of con trol 25 Maximum ...

Page 53: ...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 point ing 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 ...

Page 54: ...s 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 91 then see your dealer for servic...

Page 55: ...ting in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees ...

Page 56: ... 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 ...

Page 57: ...parking on an incline if possible 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 25 maximum ...

Page 58: ...ess 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 ...

Page 59: ...table driving conditions Towing Loads Always attach a towed load to the hitch point Remove the hitch from the ATV 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 m...

Page 60: ...cfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and relat...

Page 61: ...e 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 hi...

Page 62: ...ver maintenance interval is reached first Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Q Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 40 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...

Page 63: ...iodically and prior to storage Q E Throttle Cable ETC Switch 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary Q 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 duct for proper seal ing air leaks Drive belt 50 H 6 M 500 800 Inspect adjust replace as needed Cooling system if applicable 50 H 6 M 1...

Page 64: ...0 1600 Inspect replace as needed Q E Ignition Timing 100 H 12 M 1000 1600 Inspect X Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed Q Brake fluid 200 H 24 M 2000 3200 Ch...

Page 65: ...in lube or SAE 80 90 Lubricate Transmission Oil AGL Synthetic Gearcase Lube See page 68 Demand Drive Fluid Front Gearcase Demand Drive LT Premium Fluid See page 70 Front Prop Shaft Yoke Premium U Joint Lube Grease fittings 3 pumps maximum every 500 miles 800 km before long periods of storage or after pressure washing or submerging Front Hubs Premium Hub Lube Remove set screw in hubs Rotate wheels ...

Page 66: ...62 MAINTENANCE Lubrication Guide Front Prop Shaft Yoke Swing Arm Bushings Tie Rod Ends Front Hubs Ball Joint Axle Housing 4 or 8 o clock position end view ...

Page 67: ... Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation See page 109 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Specifications Lubricant Capacity Drain Plug Torque PS 4 PLUS Perform...

Page 68: ... the engine Allow it to idle for 30 seconds Stop the engine 3 Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely Make sure the cap is fully seated to keep the angle and depth of the stick consistent 5 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 6 Reinstall the dipstick Safe Add Oil Safe R...

Page 69: ... oil to contact skin 4 Reinstall the drain plug with a new sealing washer Torque to specification See page 63 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 be sealed with LOCTITE PST 505 or PTFE se...

Page 70: ...To drain remove the drain plug on the lower right side of the crank case 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 63 Rein stall the dipstick Tip If the sump is not drained add about 1 3 4 quarts initially 14 Place the...

Page 71: ...o 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 procedur...

Page 72: ...ender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations Oil Check 1 Position the vehicle on a level sur face 2 Remove the propshaft shield from the right side of the vehicle to access the fill plug Remove the fill plug 3 Check the oil level Add oil as needed Do not overfill 4 Reinstall the fill plug Torque to specification Gearcase Lubricant Capacity...

Page 73: ...ve the fill plug 3 Remove the transmission drain plug located on the bottom left hand side and drain the oil into an appropriate container Discard used oil properly 4 Clean and reinstall the drain plug Torque to specification 5 Add the proper amount of the recommended lubricant 6 Reinstall the fill plug Torque to specification 7 Check for leaks 8 Reinstall the propshaft shield ...

Page 74: ...ring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom right side of the unit 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely 4 Clean and reinstall the drain plug Torque to sp...

Page 75: ... looseness Replace the pads when the friction mate rial is worn to 1 mm 5 Check the security and surface condition of the disc Side Panel Removal Tip Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times 1 Remove the seat 2 Remove the push pins at the front and rear of the side panel 3 Grasp the rear of the side panel near the rear cab...

Page 76: ...and secure them in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible Make sure both marks are the same distance from the floor 4 Measure the distance between the marks and record the measurement 1 5 Move the vehicle until the chalk marks are at the rear of the tires even with the hub ...

Page 77: ...ckwise to increase or decrease spring tension Accessory springs are avail able through your Polaris dealer 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 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the thr...

Page 78: ...h Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the handlebar cover to access the handlebar bolts 2 Loosen the four handlebar 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 10 12 ft lbs 14 17 Nm t...

Page 79: ...s 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 114 for recom mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent ...

Page 80: ...ve 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 specificatio...

Page 81: ...ue Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service Item Torque Specification Front Wheel Nuts 27 ft lbs 37 Nm Rear Wheel Nuts 50 ft lbs 68 Nm Rear 50 ft lbs 68 Nm Front 27 ft lbs 37 Nm ...

Page 82: ...c type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main fil ter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur 7 Reinstall the air box cover and the seat Main Filter Pre Filter ...

Page 83: ...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...

Page 84: ...your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C Tip Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area Carburetor Engine Idle RPM Adjustment If the engine id...

Page 85: ...amaged 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 80 90 lube or an approved o ring chain spray lube See page 109 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...

Page 86: ...sting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications Use the following procedure if adjustment is required 1 Remove the chain guard 2 Loosen the chain guide 3 Loosen the two eccentric locking bolts 4 Loosen the caliper mounting bolt located on the left side...

Page 87: ...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 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...

Page 88: ... 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 cool ant 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 ...

Page 89: ... 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 funnel 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 functio...

Page 90: ...ock the parking brake 4 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring 5 Start the engine Turn the headlight on 6 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall 7 Loosen the pivot bolt and adjust t...

Page 91: ... 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 bul...

Page 92: ... 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...

Page 93: ...cle has been driven at higher speeds Immediately check the spark plug for correct color See page 90 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Inspect the electrodes for wear and carbon ...

Page 94: ...should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carbu retion 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 recommen...

Page 95: ... 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 Tak...

Page 96: ...ust 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 Lig...

Page 97: ...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 manu...

Page 98: ...d be running at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engage ment 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 ATV will be operated for ...

Page 99: ...n 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 pr...

Page 100: ...oduce 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 ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has...

Page 101: ...nal batteries remove the battery vent tube 7 Disconnect the black negative battery cable first 8 Disconnect the red positive battery cable last 9 Lift the battery out of the ATV Be careful not to tip a conventional 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 ...

Page 102: ...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 petro...

Page 103: ...ining battery charge by using a Polaris Bat tery 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 109 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained b...

Page 104: ...y 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 St...

Page 105: ...andard 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 check in 3 months 3 6 hours 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 verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At l...

Page 106: ...s to contact 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 cleaning the upper body first and the lower parts last 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 ...

Page 107: ... 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...

Page 108: ... 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 produ...

Page 109: ... Fuel Stabilizer 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 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oi...

Page 110: ... the spark plug Pour 2 3 tablespoons 30 40 ml of engine oil into the hole Tip 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 Apply dielectric grease to the inside of the spark plug cap Reinstall the cap 6 Turn the engine over several times using the electric start Oil will be forced in a...

Page 111: ...tery Storage See pages 99 100 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover Do not use plastic or coated mate rials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxid...

Page 112: ...mission in gear 3 Lock the parking brake 4 Turn the fuel valve off 5 Secure the fuel cap oil cap and seat 6 Remove the key to prevent loss during transporting 7 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars ...

Page 113: ...emand Drive LT Premium Fluid 8 oz 237 ml Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 89 ml cartridge 2871551 Premium U Joint Lu...

Page 114: ...low range only if equipped Stuck in mud or snow Shift the transmission to low range if equipped Care fully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 95 Inspect clutch sea...

Page 115: ...with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter Replace the filter Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See yo...

Page 116: ... tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer ...

Page 117: ...park plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfu...

Page 118: ...kg Hitch Towing Rating 850 lbs 385 6 kg Unbraked Trailer Towing Capacity 1210 lbs 549 kg Overall Length 75 in 190 5 cm Overall Width 45 in 114 cm Overall Height 49 in 124 5 cm Wheelbase 48 5 in 123 cm Ground Clearance 4 75 in 12 cm Minimum Turning Radius 65 in 165 cm unloaded Engine Model Number Type EH50PLE 129 4 Cycle Single Cylinder Lubrication Dry sump Engine Cooling Liquid Displacement 498 cc...

Page 119: ...vel Shock Adjustment CAM Brakes Front and Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight Single Beam 60w Taillights 12V 8 26W Brake Light 12V 26 9W Battery 12V 14AH Indicators High Temp Neutral Reverse ALTITUDE Meters Feet AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above 0 1800 0 6000...

Page 120: ...2009 2010 76 8 ___CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 ___BA50__ SCRAMBLER 500 2008 2009 2010 79 6 ___GJ45__ OUTLAW 450 2008 2009 2010 80 7 ___GJ52__ ___GP52__ OUTLAW 525 2008 2009 2010 80 7 ___LH27__ SPORTSMAN 300 2008 2009 2010 81 1 ___LH46__ SPORTSMAN 400 2008 2009 2010 80 2 ___MN50__ SPORTSMAN 500 EFI 2008 2009 2010 80 4 ___ZN55__ ___ZX55__ SPORTSMAN 550 EFI 2009 2010 80 8 ___TN55__ ___DN...

Page 121: ...olaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed...

Page 122: ... parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effectiv...

Page 123: ...by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE REMEDIES SET FORT...

Page 124: ...our original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the abov...

Page 125: ...eling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show...

Page 126: ...is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For q...

Page 127: ...components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followin...

Page 128: ...due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for perform...

Page 129: ... section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 130: ...126 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 131: ...Corrosion Removal Chrome 104 Crankcase Emission Control System 56 D Demand Drive Fluid 70 Drive Belt Wear Burn 110 Drive Chain 81 83 Drive Chain Lubrication 81 Drive Chain Slack 82 83 Drivetrain Break In 37 Driving Downhill 48 Driving in Reverse 52 Driving on a Sidehill 47 Driving on Slippery Surfaces 45 Driving Over Obstacles 51 Driving Procedures 43 Driving Through Water 50 Driving Uphill 46 E E...

Page 132: ...l System 56 O Oil Engine 63 64 Oil Transmission 68 69 Oil and Filter Change 65 67 Oil Level Engine 64 Oil Pump Priming 67 Oil Recommendations 63 Operation on Public Lands 56 Override Switch 26 P Parking Brake 30 Parking on an Incline 53 Periodic Maintenance Chart 57 60 Polaris Product List 109 Polishing the Vehicle 103 Pre Ride Checklist 40 PVT Break In 37 PVT Drying 95 PVT System 93 95 R Reverse ...

Page 133: ... 75 Tires 75 77 Front Wheel Hub Tightening 75 Tread Depth 75 Wheel Installation 76 Wheel Nut Torque 77 Wheel Removal 76 Toe Alignment 72 T Towing Loads 55 Trail Etiquette 39 Training 7 Transmission Oil 68 69 Transmission Oil Recommendations 68 Transporting the Vehicle 108 Tread Lightly 39 Turning Around on a Hill 49 Turning the Vehicle 44 V Vehicle Identification Numbers 6 Vehicle Immersion 91 W W...

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Polaris 2010 Scrambler 4X4, Owner'S Manual

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