Polaris 2008 Scrambler 500 2X4 International, Owner'S Manual

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Page 3: ...produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but info...

Page 4: ...crepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can...

Page 5: ...NTS Know Your Vehicle 5 Safety 6 Features and Controls 31 Operation 41 Emission Control Systems 59 Maintenance 60 Specifications 108 Polaris Products 111 Troubleshooting 112 Warranty 116 Maintenance L...

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Page 7: ...egulations concerning the operation of this vehicle in your area Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key...

Page 8: ...n your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The sa...

Page 9: ...d with printed materials that explain safe operating procedures Review this information on a regular basis If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer please r...

Page 10: ...rly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating a Quadri cycle S Never opera...

Page 11: ...empt to turn the Quadricycle around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid cross ing the side of a steep hill when possible S Always use...

Page 12: ...e and always maintain proper tire pressure S Never modify a Quadricycle through improper installation or use of accessories S Never exceed the stated load capacity for your vehicle Cargo must be prope...

Page 13: ...tructor Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www polarisindustries com WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this Quadricy...

Page 14: ...reduces the operator s ability to balance and control the Quadricycle which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purp...

Page 15: ...ed helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury...

Page 16: ...perating a Quadricycle could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating a Quadricycle WARNING POTENTIAL HAZAR...

Page 17: ...id exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the Quadricycle before operating Failure to properly maintain the Quadricycle WHAT CAN HAPPEN Poor maintenance increases the possibili...

Page 18: ...contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the Quadricycle during operation WARNING...

Page 19: ...excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the Quadricycle on such terrain Always use extra caution on rough slippery or loose terr...

Page 20: ...roper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain caref...

Page 21: ...res for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 53 Always check the terrain carefully before descend...

Page 22: ...n the Quadricycle around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 54 Use extra caution when turning on any hill Avoid crossin...

Page 23: ...stopped apply the auxiliary rear brake as well then lock the parking brake If the Quadricycle begins rolling backwards Keep weight uphill Never apply engine power Never apply the auxiliary rear brake...

Page 24: ...NING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the vehicle could overturn HOW TO AVOID THE HAZARD On...

Page 25: ...s and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leav...

Page 26: ...r for more information WARNING POTENTIAL HAZARD Overloading the Quadricycle or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could...

Page 27: ...ng systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased ri...

Page 28: ...not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in...

Page 29: ...steeper than 25 degrees 25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually S REVERSE operation can be dangerous even at low speeds Steering becomes diffic...

Page 30: ...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 steering and increase risk of losing control A...

Page 31: ...NJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY 305 LBS 138 kg INCLUDES WEIGHT OF OPERATOR CARGO AND ACCESSORIES Reduce speed and allow greater distance for br...

Page 32: ...y which has granted approval The approval number and serial number will also be displayed on the label 2 Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a P...

Page 33: ...ON position Release the key when the engine starts NOTE Turn off the main switch to end all electrical power to the vehicle including the lights WARNING Leaving the keys in the ignition can lead to un...

Page 34: ...the key is in the ON position and the shut off switch is in the RUN position Indicator Lights With the engine running verify the function of all indicator lights each time the vehicle is used NOTE Th...

Page 35: ...uring operation Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded Engine speed returns to idle when the lever is released This vehic...

Page 36: ...squeezing the brake lever 1 toward the handlebar The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master c...

Page 37: ...us injury or death Maintain brake fluid at the recommended level Do not overfill NOTE When checking the fluid level the vehicle must be on level ground with the handlebars straight If the fluid level...

Page 38: ...orward to engage the brake Release the brake lever 3 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards S The parking br...

Page 39: ...erious injury or death The auxiliary foot brake 1 is located on the inside of the right floorboard and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if...

Page 40: ...TE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return the valve to the ON position after refuel...

Page 41: ...N Neutral R Reverse CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling...

Page 42: ...in the ON position NOTE If the engine is cold use the choke as outlined on page 43 4 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other s...

Page 43: ...l level on the dipstick see page 66 Add the recommended oil as needed to maintain the oil level in the normal operating range 1 3 Drive slowly at first Select an open area that allows room to familiar...

Page 44: ...Wheels fasteners Inspect ensure fastener tightness 80 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 66 Coolant level if applicable Ensure proper level 84 Coola...

Page 45: ...the vehicle NOTE Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled 6 If the engine is cold pull the choke knob out until it stops...

Page 46: ...art intermittent use of the choke button pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the thro...

Page 47: ...to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin...

Page 48: ...tion warnings on all warning labels and never exceed the specified weight capacities for the vehicle Maximum Towing Capacities Refer to the specifications at the rear of this manual for towing capacit...

Page 49: ...LOADS MUST BE SECURED BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOAD...

Page 50: ...ection of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing t...

Page 51: ...trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward WARNING Failure to exercise ca...

Page 52: ...dehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into t...

Page 53: ...when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25_ maximum Use extreme caution when operati...

Page 54: ...d speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary brake as well then lock the parking brake If the vehicle begins rolling backwards...

Page 55: ...vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing using the single brake lever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the...

Page 56: ...vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll a...

Page 57: ...rear gearcases if equipped and all grease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the main...

Page 58: ...the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obs...

Page 59: ...or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines an...

Page 60: ...parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 1 Place the transmission in gear 2 Lock the parking brake 3 Always block the rear wheels on the do...

Page 61: ...engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the on...

Page 62: ...ce and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of appr...

Page 63: ...val whichever comes first Remarks Hours Calendar Miles Km J Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist Front suspension Pre Ride j ed See Pre Ride Checklist on page 42 Rear s...

Page 64: ...0 800 Inspect adjust lubricate replace if necessary J E Choke cable 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50 H 6 M 500 800 Inspect ducts f...

Page 65: ...r wear routing security apply dielectric grease to connectors subjected to water mud etc J Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts J Front wheel bearings 100 H...

Page 66: ...on Grease or grease conforming to NLG No 2 such as Conoco Superlube M or Mobilegrease Special F Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washin...

Page 67: ...65 MAINTENANCE Lubrication Recommendations 1 2 3 4...

Page 68: ...111 for the part numbers of Polaris products CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil...

Page 69: ...drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain plug and torque to 14 17 ft lbs 19 23 Nm 6 Disconnec...

Page 70: ...o drain remove the drain plug on the lower right side of the crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 13 Reinstall the d...

Page 71: ...line 1 approximately 2I from the oil tank 2 between the end of the oil tank vent fitting and the vent line s pressure relief slit 3 2 Run the engine for 10 20 seconds 3 Remove the vent line clamp If...

Page 72: ...of Premium AGL Synthetic Gearcase Lubricant See page 111 for the part numbers of Polaris products Oil Check The transmission oil dipstick 1 is located on the right side of the vehicle 1 Position the...

Page 73: ...he drain plug and wipe the magnetic end clean to remove accumulated metallic filings 6 After the oil has drained completely install a new sealing washer and reinstall the drain plug Torque to 14 ft lb...

Page 74: ...o check for correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 cm Regularly lubricate the drive chain with Polaris Chain Lube an SAE 80 90 lube or an approved o ring...

Page 75: ...and secure them in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible Make sure both...

Page 76: ...drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always maintain brake fluid at an ad...

Page 77: ...hould be changed when worn to 3 64 1 cm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activa...

Page 78: ...ing tension NOTE Accessory springs are available through your Polaris dealer Throttle Cable Freeplay 1 Locate the throttle cable adjuster at the handlebar 2 Squeeze the end of the rubber boot A and sl...

Page 79: ...dures exactly or see your Polaris dealer for service The handlebars can be adjusted for rider preference 1 Remove the handlebar cover to access the handlebar bolts 1 2 Loosen the four bolts 3 Adjust t...

Page 80: ...and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating and engine or PVT damage See your P...

Page 81: ...the decal on your vehicle and in your owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread de...

Page 82: ...the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten On vehicles with tapered rear wheel n...

Page 83: ...vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less W...

Page 84: ...cle 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 16 3 8 48 cm 95 cm deflection...

Page 85: ...ut the hitch and 45 ft lbs 61 Nm for machines with a hitch 8 Tighten the caliper mount bolt to 15 ft lbs 20 Nm 9 Remove the pin punch 10 Roll the vehicle forward checking chain tension in several plac...

Page 86: ...ck up from the tank past the pressure cap and into the radiator Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as...

Page 87: ...diator should be inspected and coolant added if necessary 1 Remove the front panel to access the radiator pressure cap 1 Remove the cap 2 If coolant is low use a funnel and slowly add coolant through...

Page 88: ...before installing the new bulb Install the replacement bulb into headlight housing and rotate clockwise firmly NOTE The bulb must be positioned so the harness installs into the lamp at the bottom 4 R...

Page 89: ...the new lamp 4 Test the taillight brakelight for proper operation 5 Reinstall the gasket and lens cover Indicator Lamp Replacement 1 Remove the instrument panel if necessary to access the back of the...

Page 90: ...lter damage could occur Breather Filter Hose CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service 1 Remov...

Page 91: ...Previously Installed Spark Plug 17 20 ft lbs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been w...

Page 92: ...e electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Recoil Housing To prevent poss...

Page 93: ...x for any water Drain and dry it if water is present 3 Turn the fuel valve off 4 Remove the spark plug 5 Turn the engine over several times using the electric start 6 Loosen the carburetor drain screw...

Page 94: ...only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engagement point the engine may be running at a speed too low to provide the adequate pinch needed t...

Page 95: ...tenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housin...

Page 96: ...hicle while it s inclined 1 Remove the arrestor clean out plug 1 from the bottom of the muffler 2 Place the transmission in neutral and start the engine 3 Purge carbon from the system by momentarily r...

Page 97: ...th clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING Battery electrolyte is pois...

Page 98: ...sconnect the hold down strap holding the battery in position and remove battery cover 2 On conventional batteries remove the battery vent tube 3 Disconnect the black negative battery cable first 4 Dis...

Page 99: ...curely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explos...

Page 100: ...as needed to maintain a full charge NOTE Power plug leads may need to be bent down so that the battery cover can be installed NOTE Battery charge can be maintained by using a Polaris Battery Tender ch...

Page 101: ...erals that are harmful to a battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging See page 96 2 Char...

Page 102: ...and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery could explode causing severe injury or death Always watch charging ti...

Page 103: ...ent charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given ch...

Page 104: ...ypes of products to come into contact with the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing c...

Page 105: ...ed contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or ex...

Page 106: ...nt Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodi...

Page 107: ...tment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from...

Page 108: ...ml of engine oil into the hole NOTE Use a section of small hose and a small plastic squeeze bottle filled with the pre measured amount of oil 4 Reinstall the spark plug Torque to specification 5 Appl...

Page 109: ...er the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Transportin...

Page 110: ...549 kg Turn Radius 75 in 190 5 cm Ground Clearance 5 5 in 14 cm Height 47 in 119 4 cm Length 75 in 190 5 cm Width 46 in 116 8 cm Seat Height 34 in 86 4 cm Dry Weight 530 lbs 240 kg Wheel Base 48 in 12...

Page 111: ...Adjustment Threaded adjuster Front Brake Fixed disc hydraulic floating caliper Rear Brake Fixed disc hydraulic floating caliper Auxiliary Brake Fixed disc hydraulic floating caliper Parking Brake Hydr...

Page 112: ...bove Meters Feet 0 1800 0 6000 160 155 1800 3700 6000 12000 152 5 147 5 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Spring Setting Meters Feet 0 1800 0 6000 10...

Page 113: ...m Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cart...

Page 114: ...se plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss...

Page 115: ...is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify...

Page 116: ...e ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel vent line Inspect and repla...

Page 117: ...s See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to...

Page 118: ...e Polaris limited warranty excludes any failures that are not caused by a defect in ma terial or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handl...

Page 119: ...it to a Polaris dealer autho rized to repair Polaris Quadricycles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANS PORTATI...

Page 120: ...118 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 121: ...119 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 122: ...120...

Page 123: ...1 Driving Downhill 53 Driving in Reverse 57 Driving on Slippery Surfaces 49 Driving Over Obstacles 56 Driving Procedures 45 Driving Safely 45 58 Driving Through Water 55 Driving Uphill 51 52 E Electri...

Page 124: ...0 S Safe Riding Gear 30 Safety Decals and Locations 27 29 Safety Training 7 Sidehilling 50 Spark Arrestor 94 Spark Plugs 89 90 Specifications 108 110 Starting the Engine 43 44 Steering Assembly 76 Sto...