Polaris Scrambler 500 4x4 Owner'S Manual Download | Manualshive

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SPECIFICATIONS

2004 Scrambler 500 4x4

Jetting Chart

Altitude

AMBIENT

TEMPERATURE

Below 40

°

F

(Below 5

°

C)

+40

°

F and above

(+5

°

C and above)

Meters

(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

5630710

Blue/Green

7041157

Silver

7041499

40

°

5131446

1+1

1800 & above

(6000 & above)

10RH

5630709

Blue/Green

7041157

Silver

7041499

40

°

5131446

1+1

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Summary of Contents for Scrambler 500 4x4

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Page 3: ...hed to the owner 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 cause cancer birth defects or other reproductive harm WARNING ...

Page 4: ...ated a Web site just for you S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustries com owner ...

Page 5: ...duction components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibite...

Page 6: ...aking it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Yo...

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Page 8: ...ME 3 VEHICLE IDENTIFICATION NUMBERS 6 SAFETY 7 FEATURES AND CONTROLS 37 OPERATION 49 EMISSION CONTROL SYSTEMS 68 MAINTENANCE AND LUBRICATION 69 SPECIFICATIONS 114 POLARIS PRODUCTS 117 TROUBLESHOOTING 118 WARRANTY 122 INDEX 125 ...

Page 9: ...rs are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 2 in the spaces provided 1 31XX 2 Frame VIN Engine Se...

Page 10: ...olaris dealer you can request this free safety training from any authorized Polaris dealer 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 strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure...

Page 11: ...on your ATV or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the machine CAUTION NOTE A note will alert you to important information or instructions A caution indicates a situati...

Page 12: ...ves boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating an ATV S Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience S Never attempt wheelies jumps or other stunts S Always inspect your ATV before each use to make sure it s in safe operating condition Always...

Page 13: ... 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 proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braki...

Page 14: ...e or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the veh...

Page 15: ...he operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the r...

Page 16: ...s the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING ...

Page 17: ...WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops WARNING ...

Page 18: ... roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways WARNING ...

Page 19: ...eases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants WARNI...

Page 20: ... 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 POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always operate the ATV at...

Page 21: ...ARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving WARNING ...

Page 22: ...ocedures and schedules described in the owner s manual POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come into contact with the rear w...

Page 23: ...V on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions WARNING ...

Page 24: ...ly rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate 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 WARNING ...

Page 25: ...bed in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25_ Practice on smaller hills before at...

Page 26: ...er s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25_ Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person...

Page 27: ...raveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 62 Always check the terrain carefully before you descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill ...

Page 28: ...rn 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 63 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the...

Page 29: ...y 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 while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is p...

Page 30: ... as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual 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 On slippery surfaces such as ice travel slowly and use extra cauti...

Page 31: ...ight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could coll...

Page 32: ...manual and on safety decals POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris...

Page 33: ...argo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 54 POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water If yo...

Page 34: ...sons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire WARNING WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in...

Page 35: ...verfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area En gine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time S Turn the fuel valve off whenever the ATV is stored or parked The engine exhaust from this...

Page 36: ...may result especially in AWD See Owner s Manual DNever operate this vehicle on HILLS steeper than 25 degrees To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually DREVERSE operation can bedangerous evenat lowspeeds Steeringbe comes difficult To prevent flipover avoid sudden braking or sharp turns DUse OVERRIDE for reverse speed limiter with caution To prevent...

Page 37: ...ions WARNING 7077920 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 ALWAYS ...

Page 38: ...lutch damage See your Owner s Manual 7079780 Under Seat Chain Freeplay Is Important Adjust Freeplay to 3 16 3 8 DO NOT Overtension See Owner s Manual Torque Nut on Eccentric Bolts To 30 Ft Lbs For models without a hitch To 40 Ft Lbs For models with a hitch 7078572 MANUFACTURED BY POLARIS IND INC DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS 7171492 CE ...

Page 39: ...nstitute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4...

Page 40: ...d 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 Engine Stop Switch 3 The engine will not start or run when the switch is in its OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency To stop the eng...

Page 41: ...time the ATV is used NOTE The taillight is on whenever the main switch key is on Turn the key off to prevent battery drain 1 Transmission Neutral Indicator 2 Transmission Reverse Indicator 3 High Temp Warning displays if engine overheats Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approve...

Page 42: ...onic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls which could cause an accident and lead to severe injury or death Always contact your dea...

Page 43: ...ake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate ...

Page 44: ...e fluid level is low add DOT 3 brake fluid only DO NOT OVERFILL See page 117 for the part numbers of Polaris products 1 2 An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidl...

Page 45: ...The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position S Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling Operating the ATV while the p...

Page 46: ...ithout skidding Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the foot brake Maintain the fluid level between the maximum and minimum marks Aggressively applying the auxiliary rear brake when backing downhill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do n...

Page 47: ...OTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return the valve to the ON position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Refer to the specification...

Page 48: ... the transmission in gear and lock the parking brake Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems 1 F N R Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the d...

Page 49: ... in the ON position NOTE If the engine is cold use the choke as outlined on page 51 4 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke will be a compression stroke and will make the rope harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling imm...

Page 50: ... 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 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 front hubs are moving the hubs ...

Page 51: ...nd 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 this procedure return the ATV to your dealer for service To continue using AWD in reverse activate the override switch and the AWD switch See page 37 Operating with only one front hub engaged could ...

Page 52: ...e 1 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 50 6 Pull only light loads 7 During the break in period change both the oil and the filter at 2...

Page 53: ...k for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain Check condition and slack refer to drive chain adjustment section lubricate when needed 9 Air cleaner element Check for dirt clean or replace 10 Steering Check for free operation noting any unusual looseness in any area 11 Loose parts Visually inspect vehicle for any damaged components or loos...

Page 54: ...ely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Nev...

Page 55: ...mum of five seconds releasing the key when the engine starts If the engine does not start release the key and wait five seconds Then activate the starter for another five seconds Repeat this procedure until the engine starts 5 If the engine slows or stops position the choke knob half way in to allow proper engine warm up 6 Vary the engine RPM slightly with the throttle to aid in warm up When the e...

Page 56: ... 4 If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 5 Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again Cold Weather Operation for 4 Cycle Engines If the ATV is used year round check the oil level frequently A rising oil level could...

Page 57: ... specifications at the rear of this manual for towing capacities When towing reduce the rear rack cargo load capacity by the amount of trailer tongue weight Never tow any trailer on a grade steeper than 15 2 3 1 3 Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death Always follow the procedures and precautions ...

Page 58: ...ions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loade...

Page 59: ...t to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 60: ...ction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning at shar...

Page 61: ...handlebars 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 Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning CAUTION WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accid...

Page 62: ...ward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side ...

Page 63: ...tly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25_ maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual ...

Page 64: ...l 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 Keep your weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake ...

Page 65: ... vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing using the single brake lever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill WARNING ...

Page 66: ...ding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the br...

Page 67: ... and rear gearcases and all grease fittings NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and...

Page 68: ... the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain WARNING ...

Page 69: ... increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehic...

Page 70: ...d 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 downhill side See illustration 4 Shut off the fuel supply ...

Page 71: ... This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphere Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set carburetion and ignition The engine and related components must be...

Page 72: ...verage vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If...

Page 73: ...lean Coolant level Pre Ride Pre Ride Replace coolant every two years Fuel and oil tanks Pre Ride Pre Ride Fill to proper levels Throttle Pre Ride Pre Ride Check operation Lights Pre Ride Pre Ride Check operation Engine stop switch Pre Ride Pre Ride Check operation Drive chain Pre Ride Pre Ride Check condition slack Steering Pre Ride Pre Ride Check for free operation Air box sediment tube Pre Ride ...

Page 74: ...d wear 10 hrs Monthly Inspect periodically Front and rear gearcase oil 100 hrs Monthly Check monthly change annually Engine cylinder head and cylinder base fasteners 25 hrs 3 months Inspect re torque required at first service only General lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc L Engine oil level oil change 100 hrs 1000 mi 6 months Check level daily break in service at...

Page 75: ...heck monthly Shift linkage 50 hrs 6 months Inspect adjust J Drive belt 50 hrs 6 months Inspect replace as needed Steering 50 hrs 6 months Inspect daily lubricate Front suspension 50 hrs 6 months Inspect lubricate tighten fasteners Rear suspension 50 hrs 6 months Inspect tighten fasteners Drive chain s 50 hrs 6 months Inspect daily adjust and lu bricate if needed Rear axle 50 hrs 6 months Inspect b...

Page 76: ...Change fluid annually J Clutches drive and driven 100 hrs 12 months Inspect clean Engine mounts 100 hrs 12 months Inspect J L Valve clearance 100 hrs 12 months Inspect adjust J Brake fluid 200 hrs 24 months Change every two years Spark arrestor 300 hrs 36 months Clean out L Idle speed As required Adjust Recoil housing As required Drain moisture out after rid ing in water J Toe adjustment As requir...

Page 77: ...hain lube or SAE 80 90 Lubricate As needed before each use in wet conditions 1 Transmission AGL Synthetic Gearcase Lube See Page 82 Change annually or at 100 hours 2 Front Gearcase Angle Drive Fluid See Page 83 Change annually or at 100 hours 3 Front Prop Shaft U joints FGrease Grease fittings 3 months 50 hours 4 Front Prop Shaft Yoke FGrease Grease fittings 3 pumps maximum 3 months 50 hours 5 Fro...

Page 78: ...75 MAINTENANCE AND LUBRICATION Lubrication Recommendations 3 1 4 2 5 9 8 6 10 7 4 or 8 o clock position end view ...

Page 79: ...NCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50 hrs 100 hrs ...

Page 80: ...77 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks ...

Page 81: ...and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is no...

Page 82: ... Remove the dipstick 1 which is located on the left side of the vehicle 4 Wipe the dipstick dry with a clean cloth Reinstall it and screw it completely in NOTE The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and read the oil level Maintain the oil level in the normal operating range 2 Do not overfill 1 ADD 8 OZ NORMAL FULL 2 ...

Page 83: ...2 Clean the area around the drain plug A which is located on the bottom of the oil tank 3 Run the engine for two to three minutes until warm then turn the engine off 4 Place a drain pan beneath the vehicle and remove the drain plug 5 Allow the oil to drain completely 6 Install a new sealing washer B on the oil drain plug NOTE The sealing surfaces on the drain plug and on the oil tank should be cle...

Page 84: ...ower right side of the crankcase Reinstall the drain plug after draining NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 14 Remove the dipstick 2 and add the recommended oil NOTE If the sump is not drained add about 1 3 4 quarts 1 66 l initially 15 Reinstall the dipstick 16 Place the gear selector in neutral and set the parking brake 1...

Page 85: ...e behind the propshaft shield 2 Add the recommended lubricant as needed to maintain the oil level at the bottom of the fill hole threads 3 Reinstall the fill plug Transmission Oil Change 1 Remove the propshaft shield from the right side of the vehicle to access the fill plug Remove the fill plug 2 Remove the transmission drain plug located on the bottom left hand side and drain the oil into an app...

Page 86: ...laris products 1 Position the ATV on a level surface 2 Remove the fill plug 1 and check the oil level 3 Add the recommended oil as needed to maintain the level at the bottom of the fill plug threads 4 Reinstall the fill plug Front Gearcase Oil Change 1 Position the vehicle on a level surface and remove the fill plug 2 Place a drain pan beneath the gearcase remove the gearcase drain plug and drain ...

Page 87: ...ings or damaged rollers Also check for correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 cm Regularly lubricate the drive chain with Polaris Chain Lube an SAE 80 90 lube or an approved o ring chain spray lube See page 117 for the part numbers of Polaris products Washing the drive chain with a high pressure washer or gasoline can cause damage to the o rings causi...

Page 88: ... illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover im...

Page 89: ...e diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid Do not overfill Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boilin...

Page 90: ...d be changed when worn to 3 64 1 cm or about the thickness of a U S dime Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliary brake system requires no adjustment NOTE Since this is a rear brake only i...

Page 91: ... either clockwise 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 handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adj...

Page 92: ...f the machine when turned fully to the left or right 4 Torque the two front bolts to 10 12 ft lbs 14 17 Nm then torque the two rear bolts A gap of up to 1 8 will remain at the rear bolts Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious person...

Page 93: ...bove 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating and engine or PVT damage See your Polaris dealer for more information about jetting the ATV for conditions in your area If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor c...

Page 94: ...e wheel Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in your owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are ins...

Page 95: ...Install the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the wheel nuts according to the wheel nut torque specifications chart NOTE All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Bolt Size Specificati...

Page 96: ...WARNING Operating the vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Mai...

Page 97: ...the following procedure if adjustment is required 1 Remove the chain guard if applicable 2 Loosen the chain guide 3 Loosen the two eccentric locking bolts 1 4 Loosen the caliper mounting bracket bolt located on the side of the swing arm 5 Insert a pin punch 2 through the sprocket hub and into the eccentric housing Adjusting or operating the ATV with improper rear drive chain slack can result in se...

Page 98: ...without the hitch and 45 ft lbs 61 Nm for machines with a hitch 8 Tighten the caliper mount bolt to 10 12 ft lbs 14 17 Nm 9 Remove the pin punch 10 Roll the ATV forward checking chain tension in several places around the chain NOTE 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 3mm clearance and ...

Page 99: ... drawn back up from the tank past the pressure cap and into the radiator Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years ...

Page 100: ...nnel and slowly add coolant through the radiator filler neck 3 Reinstall the pressure cap and secure the front panel 4 Fill the coolant recovery bottle to the upper mark on the bottle 5 Check the coolant level in the bottle frequently adding coolant as needed until the level stabilizes NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your deal...

Page 101: ...djusted vertically 1 Position the ATV on a level surface with the headlight approximately 25 ft 7 6 m from a flat wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 2 5...

Page 102: ...amp 3 Test the taillight brakelight to see that it s working 4 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 plier or similar tool pull the lamp out of the indicator panel housing 4...

Page 103: ...lamp as filter damage could occur Breather Filter Hose 1 Remove the clamps and pull the filter 1 out of the hoses NOTE It s not necessary to remove the lower hose from the engine 2 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if needed 3 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 4 Reinsta...

Page 104: ...ouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wren...

Page 105: ...osen the carburetor drain screw 1 7 Dry the spark plug and reinstall or replace it with a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the proced...

Page 106: ...r will enter the recoil housing if the starter handle is disengaged from the rope guide when under water The drain screw is located at the bottom of the recoil housing Use a wrench to remove the screw Be sure to reinstall the screw after draining the housing NOTE Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crankcase dr...

Page 107: ... running at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engagement point the engine may be running at a speed too low to provide the adequate pinch needed to prevent incomplete engagement Incomplete engagement creates excessive heat that can destroy belts and clutch covers In some cases excessive clutch wear and damage may result If the ATV w...

Page 108: ...ING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates ...

Page 109: ...ehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the s...

Page 110: ...life It can also hinder vehicle performance Follow the battery charging instructions on page 108 before installing the battery 1 Ensure that the battery is fully charged 2 Set the battery in the battery holder 3 Connect and tighten the red positive cable first 4 Connect and tighten the black negative cable last 5 Reinstall the battery cover and attach the hold down strap 6 Verify that cables are p...

Page 111: ...y other fluid to this battery The single most important thing to 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 For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will regist...

Page 112: ... 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 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 A...

Page 113: ...nd safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels NOTE Grease all zerk fittings immediately after washing and allow th...

Page 114: ... 1 Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer Follow the instructions on the container for the recommended amounts 2 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 3 Stop the engine turn the fuel valve off and drain the carburetor bowl Oil and Filter Warm the engine and change the o...

Page 115: ...cylinder walls and crankshaft bearings 7 Treat the fuel system with Polaris Carbon Clean 8 If Polaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline Engine Anti Freeze Test engine coolant strength and change if necessary Replace coolant every two years Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow l...

Page 116: ...e and remove the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope See illustration 5 Always place the transmission in gear and lock the parking brake ...

Page 117: ... 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 Dry Weight 571 lbs 259 5 kg Wheel Base 48 in 121 9 cm Engine Cooling Engine Model Number Type EH50PLE 123 4 Cycle Single Cylinder Lubrication Dry Sump Bore x Stroke 92 x 75 Displacement 499 Compression Ratio 10 2 Engine Cooling Liquid Alternator Output watts 250w 50...

Page 118: ...Shock Adjustment CAM Front Brake Fixed disc hydraulic floating caliper Rear Brake Hydraulic opposed piston caliper rear axle fixed disc Auxiliary Brake Hydraulic opposed piston caliper rear axle fixed disc Park Brake Hydraulic lock all wheel Features Headlight 2 Dual Beam 30w 30w Taillight 8 26w Brake Light 26 9w Battery 12V 14 AH DC Plug In Rear Accessory DC Socket Forward Accessory Electric Star...

Page 119: ...eters 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 5630710 Blue Green 7041157 Silver 7041499 40 5131446 1 1 1800 above 6000 above 10RH 5630709 Blue Green 7041157 Silver 7041499 40 5131446 1 1 ...

Page 120: ...mp for Gearcase Oil 2871654 Premium Drive Hub Fluid 8 oz 2872277 Premium Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogelt 2872073 Chain Lube ...

Page 121: ... en gagement Use the throttle quickly and effectively for efficient enga gement Towing pushing at low RPM low ground speed Use low range only Utility use plowing snow dirt etc 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 control and vehicle overturn Cl...

Page 122: ... 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 stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter Replace the filter Low battery...

Page 123: ...se 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 replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See y...

Page 124: ...es 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 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction...

Page 125: ...RANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES 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 handling This warranty also does not cover any ATV that has been al tered structurally modified neglected improperly maintained used fo...

Page 126: ...ou must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY 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 warranty issues Should your dealer require any additional assistance the...

Page 127: ...rized 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 will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before...

Page 128: ...ures 56 Driving Safely 56 67 Driving Through Water 64 Driving Uphill 60 61 E Electrical Switches 37 EMISSION CONTROL SYSTEMS 68 Engaging Wheel Hubs 47 Engine Cooling System 96 97 Engine Oil Check 79 E Engine Storage 112 Equipment Modifications 11 Exhaust Emission Control System 68 F FEATURES 37 48 Filter Systems 100 Front Gearcase Oil Change 83 Front Gearcase Oil Check 83 Front Wheel Hub Tightenin...

Page 129: ...ark Plug Removal Replacement 101 Spark Plugs 101 SPECIFICATIONS 114 116 Starting a Cold Engine 51 52 S Starting a Warm Engine 53 Starting the Engine 51 53 Steering Assembly 88 Stop Switch 37 Storage Tips 111 112 T TABLE OF CONTENTS 5 Taillight Brakelight Lamp Replacement 99 Throttle Cable Freeplay 88 Throttle Lever 39 Tire Tread Depth 93 Toe Alignment 85 Towing Capacities 54 Transmission Gear Sele...

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