Polaris 9922463 - Manual

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...

5 INTRODUCTION Failure to follow the warnings in this manual can result in serious injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.Read and understand ...

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...

7 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 for proper operatin...

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a Polaris vehicle. 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 e...

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 Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instruc...

15 SAFETY Operator Safety Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. Never operate this vehicle on a froz...

16 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 ...

17 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...

18 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...

19 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 ...

20 FEATURES AND CONTROLS Switches Engine Stop Switch The engine will not start or run when the switch is in the OFF position. OFF RUN Push the stop switch down to stop the engine quickly. Pull the stop switch up to the RUN position before attempt- ing to start the engine.Both the main switch and the...

22 FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle. Indicator Lights With the engine running, verify the function of all indicator lights before each use of the vehicle. Tip: The taillight is on whenever the...

23 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...

24 FEATURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control.Read this owner's manual and understand the operation of all brake s...

25 FEATURES AND CONTROLS Brakes 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 ...

26 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine start- ing procedure on page 31 for cor- rect choke and throttle settings during starting. Fuel Tank Cap Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level...

27 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. Tip: Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 1. Turn the handlebars to the full left posi- tion. 2. Insert the steering lock key and tur...

29 OPERATION Break-In Period 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 will increase the life and performance of your vehicle more than following the procedures...

30 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 Hand brake Ensure proper ope...

31 OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral.3. Lock the parking br...

32 OPERATION Starting the Engine 8. Do not press the throttle while starting the engine. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. 9. If the engine does not start, release the starte...

33 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. Start the engine and allow it to warm up. 4. Shift the transmission into gear.5. Check your surroundings and determine your path of t...

34 OPERATION Turning the Vehicle 1. Before turning, activate a turn signal to alert oth- ers of your intentions. Activate the left signal before a left turn. Acti- vate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn whil...

35 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...

36 OPERATION Driving Uphill Whenever traveling uphill, follow these pre-cautions:1. Avoid steep hills (25 ° maximum). 2. Check the terrain carefully. 3. Avoid hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill.6. Keep your feet on the footrests. ...

37 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:1. Slow down.2. Avoid hills with excessively slippery or loose surfaces.3. Avoid crossing the sides of steep hills.4. Shift your weight ...

38 OPERATION Driving Downhill When driving downhill, follow these precautions:1. Check the terrain carefully.2. Avoid hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down.5. Avoid driving downhill at an angle, which can cause the vehicle to pitch sha...

39 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 the vehicle. Keep your weight uphill.2. Lock the parking brake. Leave the transmission in forward gear. Turn the engine off. 3. Dismount on ...

40 OPERATION Driving Through Water Your Polaris vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water:1. Determine water depths and current before entering water. 2. Choose a crossing where both b...

41 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...

42 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...

43 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. 25 ° maximum

44 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...

45 OPERATION Hauling Cargo Load Distribution Accessory racks and hitches are available from your Polaris dealer. Read and understand the load distribution warnings listed on the vehicle warning labels. Never exceed the specified weights.Never carry cargo on the front of the vehicle.Cargo should be e...

46 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. Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operatio...

47 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...

48 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 ...

51 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 47. Items not listed in the chart should be lubricated at the General Lubrication interval.The a-arms and lower control arms are lubricated at the facto...

52 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil.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 u...

53 MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 47. 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...

54 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...

55 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 ...

56 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 47. Maintain the oil level at the bottom of the fill hole threads. See page 99 for the part numbers of Polaris products.The fill plug is located ...

57 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 ...

58 MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Chart beginning on page 47. Maintain the fluid level at the bottom of the fill hole threads. See page 99 for the part numbers of Polaris products....

59 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill.The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level m...

60 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View the fluid level through the...

61 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition. Check more often if brakes are used heavily under normal operation.1. Always keep ...

62 MAINTENANCE Toe Alignment Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out.1. Position the vehicle on a le...

63 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 pre- load and shock compression damping m...

64 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 1.5-3 mm of freeplay is achieved at the thumb lever. Move the throttle lever back and forth several ...

65 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.• Maintain proper tire pressure as described on the label on your vehicle and in the specifications sectio...

66 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. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 3. Place a suitable stand under the footrest f...

67 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) 50 ft. lbs. (68 Nm) 27 ft. lbs. (37 Nm)

68 MAINTENANCE Air Filter 1. Remove the seat.2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 5. Reinstall the pre-filte...

69 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. 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. Follow the adjustment procedures ...

70 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...

71 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...

72 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...

73 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...

74 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 (...

75 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...

76 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...

77 MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause burns to skin. Allow lamps to cool before servicing. Headlamp Replacement When servicing a halogen la...

78 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...

79 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 104 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...

80 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...

81 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 vehicle to a dealer before starting it, fol- low the steps outline...

82 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 ...

83 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...

84 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...

85 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...

86 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...

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

88 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 90 before installing the battery.1. Ensure that the battery ...

89 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 ...

90 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 87. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as neede...

91 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. ...

92 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 ho...

93 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 ...

94 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 ...

95 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 ...

96 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 47.• Demand drive unit (front gearcase)• Transmission• Brake fluid (change every two years and any time the fluid looks dark or con...

97 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 47. Battery Storage See pages 89-90 for storage and charging procedures. Storage Area/Covers Set the tir...

98 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....

99 POLARIS PRODUCTS Part Number 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 Synthe...

100 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 39). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range (if equipped) more frequently. Insu...

101 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...

102 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...

103 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...

104 SPECIFICATIONS * Based on EU Directive 76/432/EC Scrambler 500 4X4 International Maximum Weight Capacity 275 lbs. (125 kg) (includes weight of opera- tor, cargo and accessories) Dry Weight 570 lbs. (258.5 kg) Fuel Capacity 4 gal. (15.1 l) Engine Oil Capacity 2 qts. (1.9 l) Transmission Oil 32 oz...

105 SPECIFICATIONS Jetting Chart Clutching Chart Scrambler 500 4X4 International 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 3.818:1 Drive Ratio, Final 2.77:1 Drive Ch...

106 DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. PRODUCT IDENTIFIC...

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

109 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, te...

110 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 TWO YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states...

111 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

113 INDEX A Age Restrictions . . . . . . . . . . . . . . . . . 5 Air Filter . . . . . . . . . . . . . . . . . . . . . . 68 All Wheel Drive Switch . . . . . . . . . . 21 All Wheel Drive System . . . . . . . . . . 28 B Battery . . . . . . . . . . . . . . . . . . . . 86-91 Charging (Conventional) . . ....