2004 Polaris ATP 500 4x4 Problems and Repair Information
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Free 2004 Polaris ATP 500 4x4 manuals!
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Popular 2004 Polaris ATP 500 4x4 Manual Pages
Owners Manual - Page 6
... gone into the engineering, design, and development of your service needs during, and after, the warranty period. Have your accessories and clothing delivered right to our world-wide family of your vehicle, be performed only by a Factory Certified Master Service Dealer (MSD) Technician.
Your manual contains instructions for minor maintenance, but information about major repairs is...
Owners Manual - Page 10
... and understand your owner's manual and all aspects of age...vehicle are responsible for anyone under 16 years of vehicle safety. Know Your Vehicle
As the operator of the vehicle...specific intervals.
7 Age Restrictions
This vehicle is an off-road vehicle. A Polaris ATV is an ADULT VEHICLE... recommended maintenance program outlined in your vehicle, including safe operating procedures. A...
Owners Manual - Page 48
...periods of the vehicle. If towing the vehicle is left unattended, always place the transmission in heavy pulling situations and when operating at less than seven miles per hour ...transmission into HIGH or PARK, you experience any shifting problems.
Belt Life
To extend belt life, use low forward gear in park and lock the parking brake.
Automatic Transmission Gear Selector
The transmission...
Owners Manual - Page 49
... rope handle tightly and pull slightly until repairs can be made. Pull the rope abruptly to start and restores compression for starting possible by allowing compression to "leak" at cranking speeds. Polaris 4-cycle engines are equipped with automatic decompressors. Position the vehicle on a level surface, place the transmission in wet areas.
46 This makes...
Owners Manual - Page 52
..., accessories) is located in : 4 H = High Range 6 5 3 L = Low Range N = Neutral 7 R = Reverse P = Park (if equipped) 2 2. Check Engine Warning...engine damage could result. 8. Service Interval/Diagnostic Mode Indicator 5. The word HOT will usually clear the warning. 6. This indicator illuminates when the electrical portion of the AWD system is this indicator shows the gear the transmission...
Owners Manual - Page 57
Always inspect the vehicle before each use to ensure it's in proper working condition before each use , severe injury or death could result.
Fuel and oil tanks - All brakes - Throttle - Engine stop switch - Check for proper level at the recovery bottle if equipped.
54 Wheels - Air cleaner element - Check for proper function. 7. Tires - Check for...
Owners Manual - Page 62
... injure the driver. The rear tires will also catch the rear of the cargo box and dump the cargo. Select a level site to dump or unload the vehicle while parked on an incline....injury and damage to the vehicle. Dismount the vehicle. 4. Lift the front of the bed, damaging the vehicle and creating hazardous driving conditions. Lower the tailgate. Place the transmission in the raised position.
59...
Owners Manual - Page 69
...vehicle, turn the handlebars full left if the vehicle is the K-turn around to your right until the vehicle is on more level ground.
8'
Uphill
66 Leave transmission in the owner's manual. If the vehicle... Dismount on the uphill side of the vehicle, or on hills, and follow proper operating procedures outlined in forward and shut off the engine. 3. Avoid climbing steep hills (25_...
Owners Manual - Page 71
... 73 for service before starting the engine.
68 Perform the services outlined in the maintenance chart. CAUTION
Major engine damage can result if the vehicle is operated in water that exceeds the footrest level, take it to a dealer before starting it, follow the procedure on page 110. The following areas need special attention: engine oil, transmission oil, front...
Owners Manual - Page 76
... drain. Take the vehicle to your dealer as possible.
73 Extensive engineering and testing has been...with the instructions in this warning can result in the owner's manual. See your dealer for use on clutch components. This PVT ...service as soon as outlined in severe injury or death.
Do not hold the throttle wide open for belt slippage. Start the engine and shift the transmission...
Owners Manual - Page 79
... to serious injury or death.
Item Brake System Auxiliary Brake Tires Wheels Frame nuts, bolts, fasteners Dump Box Latch
" Air filter,
Hours/ Miles
Frequency Remarks Inspect Inspect Inspect Inspect Inspect Inspect; Perform all services at 20 hours, the equivalent odometer reading would be 200 miles. latch securely Inspect; MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
Hours...
Owners Manual - Page 82
... every two years Clean out
L
J Fuel filter
100 hrs. 100 hrs. 100 ...Cooling system hoses (500)
" Front gearcase J Clutches
(drive and driven) Engine mounts
J Valve clearance
L
J Brake fluid
Spark arrestor
" Rear axle
... Control System Service (California)
J Dealer service item
79 Frequency Remarks 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor...
Owners Manual - Page 83
... every 6 months/1000 miles. Grease fittings (3 pumps maximum) Locate grease fitting and grease with grease gun. Locate fitting on back side of storage, or after pressure washing or submerging
Item Lube Polaris Premium 4 Synthetic 0W40 DOT 3 fluid only Method Add to proper level on 10 mph average. Perform all services at whichever reading is...
Owners Manual - Page 104
Stop the engine, place the transmission in park and lock the parking brake. 2. Elevate the side of the owner's manual beginning on page 126. Wheel Removal
1. Loosen the wheel nuts slightly. 3. Remove the wheel nuts and remove the wheel.
101 Always replace tires when the tread depth measures 1/8″ (.3 cm) or less. Maintain proper tire pressure...
Owners Manual - Page 113
... very least, to take your dealer before starting the engine. Turn the fuel valve off. 3. Turn the engine over several times using the electric start the engine. Tighten the carburetor drain screw. 9. If it or not. MAINTENANCE AND LUBRICATION
Vehicle Immersion
CAUTION
If your vehicle becomes immersed, major engine damage can result if the machine is present...
Owners Manual - Page 125
....
Solution
Shift transmission to low range during loading of clutch components. low ground speed (at a higher speed or use of Warm the engine at low RPM/low ground speed. Use low range only. Poor engine performance. TROUBLESHOOTING
Drive Belt and Cover Problems
Possible Cause
Driving the ATV onto a pickup or tall trailer in gas tank, fuel lines...
Owners Manual - Page 128
... malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine
Solution
Turn fuel valve to reserve, refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten...
Owners Manual - Page 134
.... If any additional assistance they will remain in effect. We recommend the use any warranty issues. This warranty gives you specific legal rights, and you must present your dealer to resolve any Polaris Servicing Dealer to you may not apply to perform warranty service. Mixing oil brands or using non-recommended oil may not be covered by...
Owners Manual - Page 135
...Warranty or Service Bulletin repairs may not give authorization for warranty or service bulletin coverage of any kind. (Vehicles registered to Get Service
If Purchased From A Private Party: If you should consult an authorized dealer to an authorized Polaris dealer. Dealers may be authorized to Safety Recalls. You should take your warranty coverage. This policy does not apply to perform...
Owners Manual - Page 136
... part on your LSI engine, but POLARIS cannot deny warranty solely for the lack of receipts or for presenting your failure to ensure the performance of time, not to you should , however, be aware that POLARIS may be completed in materials and workmanship which produces 25 and greater horsepower and the vehicle has a six (6) or...
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