Polaris 500 2X4 Скачать руководство пользователя

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MAINTENANCE

Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor could

result in serious injury or death. Never run the engine in an enclosed area.

Remove any combustible materials from the area. Wear eye protection and

leather work gloves. Do not stand behind or in front of the vehicle while purging.

Never go under the vehicle while it's inclined.
The exhaust system can get extremely hot. Do not perform service on the spark

arrestor while the system is hot. Allow components to cool sufficiently before

proceeding.

Use the following procedure to periodically purge accumulated carbon

from the exhaust pipe/muffler.
1. Position the vehicle on a

level surface.

2. Place the transmission in

neutral.

3. Lock the parking brake.
4. Remove the arrestor clean-

out plug from the bottom

of the muffler.

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

carbon from the system.

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

Wear protective gloves.

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

step 6.

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

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

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

steps 6 to 8 until no more particles are expelled.

11. Stop the engine. Allow the arrestor to cool.
12. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

WARNING

Exhaust

Outlet

Clean-Out Plug

Содержание 500 2X4

Страница 1: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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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