Polaris 500 2X4 Owner'S Manual Download

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102

SPECIFICATIONS

* Based on EU Directive 76/432/EC

Scrambler 500 2X4

Maximum Weight Capacity

305 lbs. (138 kg) (includes weight of opera-

tor, cargo and accessories)

Dry Weight

530 lbs. (240 kg)

Fuel Capacity

3.5 gal. (13.2 l)

Engine Oil Capacity

2 qts. (1.9 l)

Transmission Oil

11.3 oz. (334 ml)

Coolant

2.25 qts. (2.13 l)

Front Rack Capacity (Accessory)

30 lbs. (13.6 kg) (Maximum)

Rear Rack Capacity (Accessory)

60 lbs. (27.2 kg) (Maximum)

Hitch Tongue Weight Capacity

85 lbs. (38.6 kg) (Rear rack capacity and

tongue weight not to exceed 60 lbs./27.2 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

46 in. (117 cm)

Overall Height

47 in. (114 cm)

Wheelbase

48 in. (122 cm)

Ground Clearance

5.5 in. (14 cm)

Minimum Turning Radius

75 in. (190.5 cm) unloaded

Engine Model Number/Type

4 Cycle, Single Cylinder

Lubrication

Dry sump

Engine Cooling

Liquid

Displacement

499 cc

Bore x Stroke

92 x 75

Alternator Output

250w @5000 rpm

Compression Ratio

10.2:1

Carburetor

BST 40

Pilot Jet

Main Jet

155

Needle Jet

Y-0M (896)

Jet Needle

6H25-94-3

Pilot Air Jet

160

Pilot Screw

2.0 turns

Ignition System

CDI

Ignition Timing

+/- 2

@ 5000 RPM

Spark Plug / Gap

BKR6E / .036 in. (.9 mm)

Summary of Contents for 500 2X4

Page 1: ......

Page 2: ...ng 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...

Page 3: ...rcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service...

Page 4: ...y 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 inten...

Page 5: ...TENTS 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...

Page 6: ...l 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...

Page 7: ...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...

Page 8: ...ion switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN ____________________________________________________________ Engine...

Page 9: ...er 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 equip ment has bee...

Page 10: ...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 distin...

Page 11: ...sonal 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 p...

Page 12: ...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 traini...

Page 13: ...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 e...

Page 14: ...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 nee...

Page 15: ...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...

Page 16: ...ual 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 drivi...

Page 17: ...low 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 whi...

Page 18: ...lways 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 manua...

Page 19: ...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 component...

Page 20: ...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 WIT...

Page 21: ...r 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...

Page 22: ...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...

Page 23: ...h 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...

Page 24: ...ssing 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 posit...

Page 25: ...on 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...

Page 26: ...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 im...

Page 27: ...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 Opera...

Page 28: ...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 le...

Page 29: ...ake 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 sys tem...

Page 30: ...mp 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...

Page 31: ...l 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 c...

Page 32: ...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 f...

Page 33: ...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...

Page 34: ...ur 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 fee...

Page 35: ...n and pressure 77 Wheels fasteners Inspect ensure fastener tightness 77 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 28 56 Coolant level Ensure proper level 73...

Page 36: ...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...

Page 37: ...ve 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...

Page 38: ...er 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 lev...

Page 39: ...he 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 spe...

Page 40: ...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 Ne...

Page 41: ...dden 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 up...

Page 42: ...less 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...

Page 43: ...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...

Page 44: ...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 yo...

Page 45: ...lined 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 ov...

Page 46: ...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...

Page 47: ...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 in...

Page 48: ...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 cou...

Page 49: ...t 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 wh...

Page 50: ...ine Avoid parking on an incline If it s unavoidable follow these precau tions 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake 4 Always block the rear wheels on the downhill...

Page 51: ...cluding 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 Po...

Page 52: ...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 approx...

Page 53: ...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 rela...

Page 54: ...rake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air filter pre filter Daily Inspect clean often replace as needed X Air box sediment tube Daily...

Page 55: ...Inspect duct for proper seal ing air leaks Drive belt 50 6 M 500 800 Inspect adjust replace as needed Cooling system 50 6 M 1000 1600 Inspect coolant strength seasonally pressure test system yearly X...

Page 56: ...t replace as needed Q E Ignition Timing 100 12 M 1000 1600 Inspect X Wiring 100 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clut...

Page 57: ...e page 56 Brake Fluid DOT 4 Only See page 63 Drive Chain s O ring chain lube or SAE 80 90 Lubricate Transmission Oil Polaris AGL Synthetic Gearcase Lube See page 60 Swing Arm Bushings XPremium All Sea...

Page 58: ...s Oil Level The oil dipstick is located on the left side of the vehicle 1 Position the vehicle on a level surface Place the transmission in neutral Lock the parking brake 2 Start the engine Allow it t...

Page 59: ...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...

Page 60: ...o 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 d...

Page 61: ...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...

Page 62: ...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 remo...

Page 63: ...llic 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...

Page 64: ...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 S...

Page 65: ...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 fre quently for the...

Page 66: ...heavily during normal opera tion 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 Chec...

Page 67: ...ecure 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 pos sible Make sure both marks are...

Page 68: ...o 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 decr...

Page 69: ...er 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 tou...

Page 70: ...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...

Page 71: ...s 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 overh...

Page 72: ...d 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 ap...

Page 73: ...ng or operating the vehicle with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications Use...

Page 74: ...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 vehicle forward checking chain tension in several plac...

Page 75: ...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 a...

Page 76: ...he 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...

Page 77: ...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...

Page 78: ...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 straigh...

Page 79: ...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 recom mended ti...

Page 80: ...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 tape...

Page 81: ...e 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...

Page 82: ...oosen 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 t...

Page 83: ...he 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...

Page 84: ...peeds Immedi ately 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 spar...

Page 85: ...hould 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 ti...

Page 86: ...esent 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 elect...

Page 87: ...he 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...

Page 88: ...oads 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...

Page 89: ...e 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 nee...

Page 90: ...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...

Page 91: ...ce 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...

Page 92: ...e 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...

Page 93: ...rely 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 explosio...

Page 94: ...ning 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...

Page 95: ...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...

Page 96: ...dard 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...

Page 97: ...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 Ri...

Page 98: ...w 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...

Page 99: ...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 periodical...

Page 100: ...lizer 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...

Page 101: ...ur 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...

Page 102: ...r storage and charging procedures Storage Area Covers 1 Make sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touch...

Page 103: ...nsmission 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 vehicle t...

Page 104: ...o exceed 60 lbs 27 2 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 46 in 117 cm Overall Height 47 in 114 cm Wheel...

Page 105: ...uster Brakes Front Fixed disc hydraulic floating caliper Brakes Rear Fixed disc hydraulic floating caliper Brake Auxiliary Fixed disc hydraulic floating caliper Brake Parking Hydraulic lock all wheel...

Page 106: ...Premium Demand Drive Hub Fluid 2 5 gal 9 5 l 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 3 oz 89 ml 2...

Page 107: ...ow 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...

Page 108: ...ded fuel Replace 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 Insp...

Page 109: ...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...

Page 110: ...s Worn or defective spark 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 vo...

Page 111: ...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 improper hand...

Page 112: ...it to a Polaris dealer autho rized to repair Polaris Quadricycles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANS PORTATIO...

Page 113: ...111 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 114: ...112 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 115: ...rrosion Removal Chrome 97 D Drive Belt Wear Burn 105 Drive Chain 70 72 Drive Chain Lubrication 70 Drive Chain Slack 71 72 Drivetrain Break In 31 D Driving Downhill 41 Driving in Reverse 45 Driving on...

Page 116: ...rking Brake 26 Parking on an Incline 48 Periodic Maintenance Chart 50 54 Polaris Product List 104 Polishing the Vehicle 96 Pre Ride Checklist 33 PVT Break In 31 PVT Drying 88 PVT System 86 88 R Revers...

Page 117: ...emoval 78 Toe Alignment 65 Towing Loads 47 Training 7 Transmission Oil 60 61 Transporting the Vehicle 101 Turning Around on a Hill 42 Turning the Vehicle 37 V Vehicle Identification Numbers 6 Vehicle...

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