Polaris 9922077 - Manuals

4 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazar...

6 INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. The ignition switch must be replaced if all keys are lost. Vehicle Model Number: ______________________________________...

7 SAFETY Safety Training When you purchased your new Polaris vehicle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this informa- tion on a regular basis. If you purchased your vehicle from a party ...

8 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Always wear a helmet that meets or exceeds established safety stan- dards.Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.Approved helmets in Europe, Asia and ...

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing marki...

10 SAFETY Operator Safety Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual fo...

17 SAFETY Operator Safety Never operate this vehicle on a frozen body of water. Never modify a Quadricycle through improper installation or use of accessories. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow th...

18 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels ...

19 SAFETY Safety Labels and Locations Discretionary Warning WARNING• Never operate this ATV on HILLS steeper 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 be...

20 SAFETY Safety Labels and Locations “No Passenger” Warning WARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Tire Pressure/Load Warning WARNINGImproper tire pressure or overloading can cause loss of control. Loss of control can re...

21 SAFETY Safety Labels and Locations Age 16 Warning WARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or death.NEVER operate this ATV if you are under age 16. 7175374 Clutch Cover Warning WARNING• Moving parts hazard under belt-clutch guard. To prevent ...

22 FEATURES AND CONTROLS Switches Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and press the override switch. WARNING! Pressing the override switch while the throttle is open can cause loss of control...

23 FEATURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. Indicator Lights With th...

24 FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks d...

25 FEATURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.Always test brake lever travel and master cylinder fluid level before riding. When sque...

26 FEATURES AND CONTROLS Parking Brake 1. Place the transmission in gear. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever.5. To release the parking brake lock, squeeze and release ...

27 FEATURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxiliary rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary b...

28 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 34 for correct choke and throttle settings during start- ing. Fuel Tank Cap Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level s...

29 FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle.F: Forward GearN: NeutralR: ReverseTo shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE: Shifting gears with the e...

30 OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for y...

31 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 28. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 56. Add oil as needed to maintain the level in the proper range. 3. Drive slowly at first. Select...

32 OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle. 3. Never carry a p...

33 OPERATION Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel En...

34 OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Place the transmission in neutral.3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not en...

36 OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8.2. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 3. Squeeze the brake lever.4. Start the engine and allow it to warm up.5. Shift the transmission into gear.6. Check your surroundings an...

37 OPERATION Turning the Vehicle To turn, steer in the direction of the turn, leaning your upper body to the inside of the 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 ...

38 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Do not operate on excessively rough, slippery or loose terrain.2. Slow down when entering slippery areas.3. Maintain a high level...

39 OPERATION Driving Uphill Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions:1. Drive straight uphill.2. Avoid steep hills (25 ° maximum). 3. Always check the...

40 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down.2. Avo...

41 OPERATION Driving Downhill When driving downhill, follow these precautions:1. Avoid steep hills (25 ° maximum). 2. Avoid hills with excessively slippery or loose 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 ...

42 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill.2. Leave the transmission in forward and shut off the engine.3. Dismount on the ...

43 OPERATION Driving Through Water Your Polaris vehicle can operate through water with a maximum recom- mended depth equal to the bottom of the footrests. Follow these proce- dures when operating through water:1. Determine water depths and current before entering water. 2. Choose a crossing where bo...

44 OPERATION Driving Over Obstacles Follow 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 caution3. Never operate over large obstacles.4. Avoid hazards such as logs, rocks and low branches.

45 OPERATION Driving in Reverse Follow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.2. Always avoid backing downhill.3. Back slowly.4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles.6. Never open the throttle suddenly...

46 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo:REDUCE SPEED AND ALLOW GREATER DIST...

47 OPERATION Hauling Cargo Load Distribution Accessory racks and hitches are available from your Polaris dealer. Read and understand the load distribu- tion warnings listed on the vehicle warning labels. Never exceed the specified weights.Cargo weight should be evenly distributed (1/3 on the front r...

48 OPERATION Parking on an Incline 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 side.5. Turn the fuel valve off.

49 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine desi...

50 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.Inspect, clean, lubricate, adjust and replace part...

51 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a „ could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these ...

55 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 50. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS Performance Synthetic ...

56 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendat...

57 MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Always change the oil filter whenever changing oil.1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of...

58 MAINTENANCE Oil and Filter Change 8. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 9. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Make sure the gasket from...

59 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.1. Clamp or pinch off the vent line approximately two inches (5 cm) from the oil tank, between the end of the oil ...

60 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Maintain the oil level within the SAFE operating range on the dipstick. Transmission Oil Recommendations Oil Check 1. Position the vehicle on...

61 MAINTENANCE Transmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan beneath the transmission oil drain plug area. 3. Loosen the jam nut.4. Turn the adjuster bolt in to allow the removal of the drain plug. 5. Remove the drain plug and wipe the magnetic end clea...

62 MAINTENANCE Brakes Brake Fluid An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill.Once open, a bottle of brake fluid absorbs moisture from the air, which causes the boiling temperatu...

64 MAINTENANCE Brakes Brake Check Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used 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. ...

65 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustme...

66 MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Rear Suspension The rear suspension spring preload and shock compression damping may...

67 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar.1. Slide the boots off the inline cable adjuster sleeve. Loosen the adjuster locknut. 2. Turn the adjuster until 1.6-3 mm of freeplay exists at the lever. Move the throttle lever back and forth several times while...

68 MAINTENANCE Handlebars WARNING! Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see ...

69 MAINTENANCE Carburetor Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher. Above 1800 meters the engine air/fuel mixture becomes too rich and the engine loses approximately 3% of its...

70 MAINTENANCE Drive Chain Drive Chain Lubrication The drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubri- cated.Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-ring...

71 MAINTENANCE Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three positions. At this point the chain should have 3...

72 MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or back- ward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position. 7. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch...

73 MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.As coolant operating temperature increases, the expanding (...

74 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water.Replace the coolant any time the cooling system has been drai...

75 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Headlamp Replaceme...

76 MAINTENANCE Lights Taillight/Brakelight Lamp Replacement 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp.3. Apply dielectric grease to the socket and install the new lamp. 4. Test the taillight/brake light for p...

77 MAINTENANCE Tires Operating your vehicle 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. Always follow all tire maintenance procedures as outlined in this ma...

78 MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. 2. Loosen the wheel nuts slightly.3. Safely place jackstands under the vehicle. 4. Remove the wheel nuts. Remove the wheel. Wheel Installation 1. Place the wheel on ...

79 MAINTENANCE Tires Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loos- ened for service. Item Torque Specification Front Wheel Nuts 27 ft. lbs. (37 Nm) Rear Wheel Nuts 50 ft. lbs. (68 Nm) Rear 50 ft. lbs. (68 Nm) Front 27 ft. lbs. (37 Nm)

80 MAINTENANCE Air Filter 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. 2. Remove the seat.3. Release the air box cover clips, and remove the air box cover. 4. Loosen the clamp and remove the filter. 5. Remove the pre-filter from the main filter....

82 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 102 for the recom- mended spark plug type and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. S...

83 MAINTENANCE Spark Plugs Spark Plug Condition Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service.The tip should not be...

84 MAINTENANCE Vehicle Immersion If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.If it's impossible to take your vehicle to a dealer before starting it, fol- low the step...

85 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 ...

86 MAINTENANCE PVT System 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 modifica...

87 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the...

88 MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing.1. Move the vehicle out of the water.2. Remove the PVT drain plug. Allow the water to drain completely. Reinstall th...

89 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Bat...

90 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear.2. Lock the parking brake.3. Disconnect the battery hold-down strap.4. Remove the battery cover.5. On conventional batteries, remove the battery vent tube.6. Disconnect the black (negative) battery cable first.7. Disconnect the...

91 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 93 before installing the battery.1. Ensure that the battery ...

92 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed ...

93 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 90. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as neede...

94 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 mos. ...

95 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping the vehicle clean will extend the life of components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellent...

96 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components. Avoid directing the water stream at the following items: If an informational or graphic label becomes illegible o...

97 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to ...

98 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as ...

99 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 50.• Transmission• Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/...

100 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 50. Battery Storage See page 92-94 for storage and charging procedures. Storage Area/Covers 1. Make sur...

101 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission 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...

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) C...

103 SPECIFICATIONS Jetting Chart Clutching Chart Scrambler 500 2X4 Driving System Type PVT (Polaris Variable Transmission) Shift Type Side Lever (F/N/R) Gear Reduction, Reverse 3.05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 12/36 76P Drive Chain 520 O-Ring Tires/Pressure, Front 23 x 7-10 (...

104 POLARIS PRODUCTS Part # Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic ...

105 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Starting out going up a steep incline Use low range (if equipped) or turn around using the K- turn (see page 42). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range (if equipped) more frequently. Insu...

106 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connection...

107 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too...

108 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective sp...

109 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective...

110 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES N...

111 MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

113 INDEX A Air Filter . . . . . . . . . . . . . . . . . . . . . . 80 B Battery . . . . . . . . . . . . . . . . . . . . 89-94 Charging (Conventional) . . . . . 93 Charging (Sealed) . . . . . . . . 93-94 Fluid (Conventional) . . . . . . . . . 92 Installation . . . . . . . . . . . . . . . . 91 Removal...