Page 2 - WARNING; Improper vehicle use can result in SEVERE INJURY or DEATH.
WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER operate: S without proper training or instruction. S at speeds too fast for your skills or the conditions. S on public roads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steer...
Page 3 - The engine exhaust from this product contains
A card containing important ATV safety information should be attached 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. WARNING The engine exhaust from this product contains chemicals known to the State of C...
Page 4 - WELCOME; RANGER
1 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles• All-terrain vehicles (ATVs)• RANGER utility vehicles • Victory motorcyclesWe believe Polaris sets a ...
Page 6 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Features and Controls . . . . . . . . . . . . . . . . . . . 26Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Emis...
Page 7 - INTRODUCTION; CAUTION; NOTICE
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...
Page 9 - Vehicle Identification Numbers; spaces provided. Remove the spare key and store it in a safe place. An
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. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one o...
Page 10 - SAFETY; Safety Training; your new ATV, your dealer instructed you on the authorized ATV; available to you and your eligible family members. This; . You were also provided with; cle are thoroughly inspected at specific intervals.; FOR MORE INFORMATION ABOUT ATV SAFETY, call the
7 SAFETY Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongl...
Page 11 - Safe Riding Gear; Helmet
8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established ...
Page 12 - Eye Protection; Do not depend on eyeglasses or sunglasses for eye protection. When-; Gloves; Always wear long sleeves and long pants to protect arms and legs.; Equipment Modifications
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...
Page 13 - Safety Warnings; Operating Without Instruction
10 SAFETY Safety Warnings Failure to operate the ATV 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 for pr...
Page 14 - Handling Gasoline
11 SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline.• Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or spa...
Page 15 - Protective Apparel
12 SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident.Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles...
Page 16 - Operating on Pavement
13 SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn.Avoid operating the ATV on pavement. ATV tires are des...
Page 17 - Physical Control of the ATV
14 SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it co...
Page 18 - Descending Hills Improperly
15 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn.• Always follow proper procedures for travel- ing down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling down- hill. S...
Page 19 - Stalling While Climbing a Hill
16 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.• Always maintain a steady speed when climbing a hill. If all forward speed is lost:• Keep body weight uphill.• Apply the single-lever brake gr...
Page 20 - Operating on Slippery Terrain
17 SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.Do not operate on excessively rough, slippery or loose terrain. Always use extra cau...
Page 21 - Operating Improperly in Reverse
18 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 54. Before shifting into reverse gear, always check for obstacles or people...
Page 22 - Operating Over Obstacles
19 SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn.Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always foll...
Page 23 - Improper Cargo Loading
20 SAFETY Safety Warnings Improper Cargo Loading Overloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident.• Never exceed the stated load capacity for this ATV.• Cargo should be properly distributed and securely attached.•...
Page 24 - Operating a Damaged ATV; Hot Exhaust Systems
21 SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills S...
Page 25 - Safety Labels and Locations; labels shown in this manual differ from the labels on your vehicle,; General Warning
22 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 ...
Page 26 - Discretionary Warning
23 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...
Page 27 - “No Passenger” Warning
24 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...
Page 28 - Age 16 Warning; Reverse Override Warning
25 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 ...
Page 29 - FEATURES AND CONTROLS; Switches; Override Switch; The override switch also allows activation of All Wheel Drive in; Engine Stop Switch; Move the stop switch either left or right to; Main Key Switch
26 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...
Page 30 - Headlight Switch; lights from high beam to low beam. The key must be in the ON position; All Wheel Drive Switch; See page 36 for all wheel drive information.; Indicator Lights; each use of the vehicle.
27 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. All Wheel Drive Switch S...
Page 31 - Throttle Lever
28 FEATURES AND CONTROLS Throttle Lever Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.Failure to...
Page 32 - Brake Lever
29 FEATURES AND CONTROLS Brake Lever Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward ...
Page 33 - Parking Brake; Locking the Parking Brake
30 FEATURES AND CONTROLS Parking Brake Locking the 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 ...
Page 34 - Auxiliary Foot Brake; reduce
31 FEATURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxiliary 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 brake ...
Page 35 - Brake Fluid; fluid level drops. If the fluid level is low and the diaphragm is not
32 FEATURES AND CONTROLS 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.Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidl...
Page 36 - Hand Brake
33 FEATURES AND CONTROLS Brake Fluid Hand Brake Check the brake fluid level in the master cylinder before each use of the vehicle. The master cylinder is located on the left handlebar. Maintain the fluid level 1/4" (6 mm) below the top edge of the master cylinder. Do not overfill.1. Position the...
Page 37 - Choke
34 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 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...
Page 38 - Automatic Transmission Gear Selector; The transmission gear selector is located; Whenever the ATV is left unattended,
35 FEATURES AND CONTROLS Automatic 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...
Page 39 - Engaging AWD
36 FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light will be on.When in AWD, the fr...
Page 40 - Disengaging AWD; one side, it's likely that one front hub is engaged. If both hubs are
37 FEATURES AND CONTROLS All Wheel Drive (AWD) System Disengaging AWD Although the hubs normally disengage when operating in reverse, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, it's likely that one front hub is engaged. If both hubs are engaged, steering ef...
Page 41 - OPERATION
38 OPERATION Failure to operate the ATV 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 your ...
Page 42 - Engine and Drivetrain Break-in; Fill the fuel tank with gasoline. See page 34. Always exercise
39 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 66. Add oil if neces- sary to maintain the level in the safe operating range. 3. ...
Page 43 - Safe Operation Practices
40 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...
Page 44 - Know Your Riding Area/Tread Lightly; terrain, avoid littering, and always stay on the designated trails.; Trail Etiquette; Always practice good etiquette when riding. Allow a safe distance
41 OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by con- tacting your Polaris dealer, a local...
Page 45 - ATV before each use to make sure it's in safe operating condition.; Item
42 OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel Ensure prope...
Page 46 - Starting the Engine; choke knob out until it stops. If
43 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...
Page 48 - Driving Procedures; brakes on level surfaces.
45 OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8.2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear.5. Check your surroundings and determine your path of trav...
Page 49 - Turning the Vehicle
46 OPERATION Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To...
Page 50 - Driving on Slippery Surfaces; Never apply the brakes during a skid. Correct a skid by turning the
47 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. Engage AWD before whe...
Page 51 - Driving Uphill; throttle suddenly could cause the ATV to flip over backwards.
48 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...
Page 52 - unavoidable
49 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...
Page 53 - Driving Downhill; may cause the rear wheels to lock, which could result in loss of con-
50 OPERATION Driving Downhill When driving downhill, follow these precautions:1. Avoid steep hills (25 ° maximum). 2. Shift body weight uphill.3. Drive straight downhill.4. Slow down. Excessive speed when traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually. Applying th...
Page 54 - cle is pointing straight uphill.
51 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 ...
Page 55 - Driving Through Water; If it’s unavoidable to enter water deeper than the footrest level:
52 OPERATION Driving Through Water Your ATV can operate through water with a maxi- mum recommended depth equal to the bottom of the footrests. Follow these pro- cedures when operating through water:1. Determine water depths and current before entering water. 2. Choose a crossing where both banks hav...
Page 56 - Driving Over Obstacles; ards such as logs, rocks and low hanging branches.
53 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles:1. Always check for obstacles before operating in a new area.2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. Travel slowly and us...
Page 57 - Driving in Reverse; lightly
54 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...
Page 58 - Parking on an Incline
55 OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Place the transmission in gear.3. Lock the parking brake.4. Always block the rear wheels on the downhill side.5. Turn the fuel valve off.
Page 59 - Hauling Cargo
56 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...
Page 60 - Towing Loads
57 OPERATION Hauling Cargo Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual.Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough...
Page 61 - EMISSION CONTROL SYSTEMS; Noise Emission Control System
58 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle...
Page 62 - MAINTENANCE; Periodic Maintenance Chart; inspected and serviced more frequently.; Severe Use Definition; cause or see your dealer.
59 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...
Page 63 - Maintenance Chart Key; Perform these operations more often for vehicles subjected to
60 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 ...
Page 67 - Lubrication Guide
64 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 59. Items not listed in the chart should be lubricated at the General Lubrication interval. See page 111 for the part numbers of Polaris products.The a-...
Page 69 - Engine Oil; Oil Recommendations; PLUS; Oil Specifications
66 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...
Page 70 - Oil and Filter Change
67 MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. 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...
Page 71 - Prime the oil pump using the procedure on page 69.
68 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...
Page 72 - Oil Pump Priming; If
69 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 ...
Page 73 - Transmission Oil; Transmission Oil Recommendations
70 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. Maintain the oil level at the bottom of the fill hole threads. See page 111 for the part numbers of Polaris products.The fill plug is located...
Page 74 - Oil Change; access the fill plug. Remove the fill plug.
71 MAINTENANCE Transmission Oil Oil Change 1. Position the vehicle on a level surface.2. Remove the propshaft shield from the right side of the vehicle to access the fill plug. Remove the fill plug. 3. Remove the transmission drain plug located on the bottom left-hand side and drain the oil into an ...
Page 75 - Front Gearcase Fluid; part numbers of Polaris products.; Front Gearcase Fluid Recommendations; Fluid Change; Position the vehicle on a
72 MAINTENANCE Front Gearcase Fluid Always check and change the front gearcase fluid at the intervals out- lined in the Periodic Maintenance Chart beginning on page 59. Maintain the fluid level at the bottom of the fill hole threads. See page 111 for the part numbers of Polaris products. Front Gearc...
Page 76 - Brakes; Brake Inspections
73 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommended to keep the brake syst...
Page 77 - Toe Alignment
74 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (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 alignmen...
Page 78 - Steering Assembly
75 MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Rear Spring The ...
Page 79 - Handlebars
76 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. WARNING! Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or dea...
Page 80 - Tires; Tire Tread Depth; Always replace tires; Front Wheel Hub Tightening
77 MAINTENANCE Tires 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. Always follow all tire maintenance procedures as outlined in this manual...
Page 81 - Wheel Removal; Wheel Installation
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. WARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 3. Place a suitable stand under the f...
Page 82 - Wheel Nut Torque Specifications; Rear
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)
Page 83 - Air Filter
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....
Page 85 - Carburetor; Carburetor/Engine Idle RPM Adjustment
82 MAINTENANCE Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine l...
Page 86 - Drive Chain; Drive Chain Lubrication; numbers of Polaris products.
83 MAINTENANCE Drive Chain Drive Chain Lubrication Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated.Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing ...
Page 87 - Rear Drive Chain Slack; Loosen the caliper mounting
84 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...
Page 89 - Cooling System; and ready to use. Do not dilute with water. See page 111 for the part; Recovery Bottle Coolant; The recovery bottle is located on
86 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 (...
Page 90 - Radiator Coolant
87 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...
Page 91 - Lights; Headlight Beam Adjustment; the following procedure to make the adjustment.
88 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in n...
Page 92 - lights are adjusted properly for best visibility.; Headlamp Replacement; new bulb. Install the replacement bulb into the headlight housing
89 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...
Page 93 - Lamp Replacement
90 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...
Page 94 - Spark Plugs; Spark Plug Recommendations; Spark Plug Inspection; Plug Condition
91 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 116 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always u...
Page 95 - Spark Plug Condition; Normal Spark Plug; end. There may be a carbon layer over the entire nose. Generally, the
92 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...
Page 96 - Vehicle Immersion
93 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, 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 ATV to a dealer before starting it, follow the steps outlined belo...
Page 97 - Spark Arrestor; Place the transmission in
94 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 ...
Page 98 - PVT System
95 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...
Page 99 - force exerted on the movable drive sheave by the flyweights also
96 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...
Page 100 - PVT Drying; Reinstall the drain plug.
97 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...
Page 101 - Battery; cleaning solution or tap water into a conventional battery.
98 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...
Page 102 - Battery Removal; battery sideways, which could spill electrolyte.
99 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...
Page 103 - Battery Installation; teries do not have a vent tube). The vent tube must be free of
100 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 102 before installing the battery.1. Ensure that the batter...
Page 104 - Battery Storage
101 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...
Page 105 - fully charged
102 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 99. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as need...
Page 106 - State of
103 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....
Page 107 - Cleaning and Storage; Washing the Vehicle; but it can also extend the life of various components.; and the lower parts last.; Washing Tips
104 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden h...
Page 108 - safety; Polishing the Vehicle; Polishing Tips
105 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 and could remove paint and decals. Avoid directing the water stream at the follow- ing items: If an informational...
Page 109 - Removing Corrosion
106 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...
Page 110 - Storage Tips; Clean the Exterior; Follow the instructions on the container for the recommended; Oil and Filter
107 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...
Page 111 - Fluid Levels; be forced in and around the piston rings and ring lands, coating the
108 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 59.• Demand drive unit (front gearcase)• Transmission• Brake fluid (change every two years and any time the fluid looks dark or co...
Page 112 - Inspect and Lubricate; in the Periodic Maintenance Chart beginning on page 59.; See pages 101-102 for storage and charging procedures.
109 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 59. Battery Storage See pages 101-102 for storage and charging procedures. Storage Area/Covers Set the ...
Page 113 - Transporting the Vehicle
110 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...
Page 114 - POLARIS PRODUCTS; Description
111 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 ...
Page 115 - TROUBLESHOOTING; Possible Cause
112 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 51). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range (if equipped) more frequently. Insu...
Page 116 - Engine Doesn't Turn Over
113 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...
Page 117 - Engine Pings or Knocks
114 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...
Page 118 - Engine Stops or Loses Power
115 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...
Page 119 - SPECIFICATIONS
116 SPECIFICATIONS * Based on EU Directive 76/432/EC Scrambler 500 4X4 Maximum Weight Capacity 275 lbs. (125 kg) (includes weight of opera- tor, cargo and accessories) Dry Weight 571 lbs. (259.5 kg) Fuel Capacity 3.5 gal. (13.2 l) Engine Oil Capacity 2 qts. (1.9 l) Transmission Oil 32 oz. (946 ml) F...
Page 120 - Jetting Chart
117 SPECIFICATIONS Jetting Chart Clutching Chart Scrambler 500 4X4 Driving System Type Automatic PVT (Polaris Variable Transmission) Shift Type Side Lever (F/N/R) Gear Reduction, Reverse 4.74:1 Gear Reduction, Forward 3.06:1 Drive Ratio, Front 2:1 Drive Ratio, Final 2.77:1 Drive Chain 520 O-Ring Tir...
Page 121 - WARRANTY; LIMITED WARRANTY; REGISTRATION
118 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for...
Page 123 - HOW TO OBTAIN WARRANTY SERVICE; SPARK ARRESTOR
120 WARRANTY 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 SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some state...
Page 124 - Exported Vehicles; How to Get Service
121 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA- TION.This policy does not apply to vehicles that have received authorization for ex...
Page 125 - Notice
122 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of th...
Page 127 - MAINTENANCE LOG
124 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
Page 129 - INDEX
126 INDEX A Air Filter . . . . . . . . . . . . . . . . . . . . . 80 All Wheel Drive Switch. . . . . . . . . . 27 All Wheel Drive System . . . . . . . 36-37 AWD Switch . . . . . . . . . . . . . . . . . . 36 AWD System . . . . . . . . . . . . . . . . 36-37 B Battery . . . . . . . . . . . . . . . . . ....