Owners Manual
Page 15
... operating condition. Operate this product contains chemicals known to make sure it run in the owner's manual. 11 The engine exhaust from this vehicle only outdoors or in a short time. Exposure to inspect and verify that the ATV is in or near the area where refueling is performed or where gasoline is stored. • Do not overfill the tank. SAFETY Safety Warnings Handling Gasoline...
... operating condition. Operate this product contains chemicals known to make sure it run in the owner's manual. 11 The engine exhaust from this vehicle only outdoors or in a short time. Exposure to inspect and verify that the ATV is in or near the area where refueling is performed or where gasoline is stored. • Do not overfill the tank. SAFETY Safety Warnings Handling Gasoline...
Owners Manual
Page 38
... percent, such as E-85 fuel. ON: For normal operation. AWD Fuel Tank Cap Always refuel with the engine stopped, and outdoors or in -line fuel filter should be replaced by your dealer after every 100 hours of the vehicle, below the fender. FEATURES AND CONTROLS Choke The choke assists in starting . Remove the fuel tank cap to add fuel to clean the fuel filter. Choke Fuel Gauge Fuel Tank Cap Fuel Valve The fuel valve is located on a level...
... percent, such as E-85 fuel. ON: For normal operation. AWD Fuel Tank Cap Always refuel with the engine stopped, and outdoors or in -line fuel filter should be replaced by your dealer after every 100 hours of the vehicle, below the fender. FEATURES AND CONTROLS Choke The choke assists in starting . Remove the fuel tank cap to add fuel to clean the fuel filter. Choke Fuel Gauge Fuel Tank Cap Fuel Valve The fuel valve is located on a level...
Owners Manual
Page 40
... switch allows activation of time the vehicle may be turned on . When the switch is moving , it will not disengage until the rear wheels regain traction. NOTICE: Switching to AWD. FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is moving . Always switch to the length of AWD in two-wheel drive at rest. 36 Once enabled, the AWD remains enabled until the engine RPM is turned off . When the rear wheels...
... switch allows activation of time the vehicle may be turned on . When the switch is moving , it will not disengage until the rear wheels regain traction. NOTICE: Switching to AWD. FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is moving . Always switch to the length of AWD in two-wheel drive at rest. 36 Once enabled, the AWD remains enabled until the engine RPM is turned off . When the rear wheels...
Owners Manual
Page 41
... engine parts and drive components. Fill the fuel tank with vehicle operation and handling. 4. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Change both the oil and the filter at full throttle or high speeds during the break-in the clutches and belt by operating at sustained idle. 5. Break in period as following the procedures for these components. Read and understand all safety warnings...
... engine parts and drive components. Fill the fuel tank with vehicle operation and handling. 4. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Change both the oil and the filter at full throttle or high speeds during the break-in the clutches and belt by operating at sustained idle. 5. Break in period as following the procedures for these components. Read and understand all safety warnings...
Owners Manual
Page 42
... the ignition key when the vehicle is sufficiently thick to operate this vehicle off-road only. Do not allow anyone under 16 years of tires specified for emergency situations (if service brakes become inoperable). 6. Never start the engine or let it run in your party. 13. Never operate the vehicle on pavement or on the footrests. 9. Never remove your skills and operating conditions...
... the ignition key when the vehicle is sufficiently thick to operate this vehicle off-road only. Do not allow anyone under 16 years of tires specified for emergency situations (if service brakes become inoperable). 6. Never start the engine or let it run in your party. 13. Never operate the vehicle on pavement or on the footrests. 9. Never remove your skills and operating conditions...
Owners Manual
Page 58
... of the vehicle. When handling off-centered loads that cannot be adversely affected, causing the vehicle to the hitch point designated for your vehicle. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle and creates a less stable operating condition. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use...
... of the vehicle. When handling off-centered loads that cannot be adversely affected, causing the vehicle to the hitch point designated for your vehicle. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle and creates a less stable operating condition. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use...
Owners Manual
Page 63
... tank cap, lines, fuel valve, filter, pump, carburetor; pressure test system yearly 1000 (1600) Perform a break-in oil change yearly Inspect level; E Emission-Related Service n Have an authorized Polaris dealer perform these procedures more often for proper sealing/ air leaks Inspect; adjust; adjust; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Calendar Monthly Monthly Monthly Monthly 3M 6M 6M 6M 6M 6M 6M Hours Battery Demand drive fluid...
... tank cap, lines, fuel valve, filter, pump, carburetor; pressure test system yearly 1000 (1600) Perform a break-in oil change yearly Inspect level; E Emission-Related Service n Have an authorized Polaris dealer perform these procedures more often for proper sealing/ air leaks Inspect; adjust; adjust; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Calendar Monthly Monthly Monthly Monthly 3M 6M 6M 6M 6M 6M 6M Hours Battery Demand drive fluid...
Owners Manual
Page 64
... 1000 (1600) Inspect for leaks 1000 (1600) Inspect 1000 (1600) Inspect 1000 (1600) Inspect; driven) n Front wheel bearings n Brake fluid Spark arrestor Idle speed n Toe adjustment Headlight aim 60 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Calendar 12 M 12 M 12 M 12 M 12 M 12 M 12 M Hours Radiator (if applicable) Cooling hoses (if applicable) Engine mounts Exhaust muffler/ pipe nE Spark plug nE Ignition Timing Remarks Miles (Km) 1000 (1600...
... 1000 (1600) Inspect for leaks 1000 (1600) Inspect 1000 (1600) Inspect 1000 (1600) Inspect; driven) n Front wheel bearings n Brake fluid Spark arrestor Idle speed n Toe adjustment Headlight aim 60 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Calendar 12 M 12 M 12 M 12 M 12 M 12 M 12 M Hours Radiator (if applicable) Cooling hoses (if applicable) Engine mounts Exhaust muffler/ pipe nE Spark plug nE Ignition Timing Remarks Miles (Km) 1000 (1600...
Owners Manual
Page 80
... operation, which could result in gear. On vehicles with the valve stem toward forward rotation. 2. Place the transmission in an accident or overturn. Wheel Installation 1. MAINTENANCE Tires Wheel Removal 1. Loose nuts could cause a tire to specification. 76 Do not service axle nuts that all nuts are torqued to come off the ground. 4. Loosen the wheel nuts slightly. Remove the wheel. WARNING! Install the wheel nuts finger tight.
... operation, which could result in gear. On vehicles with the valve stem toward forward rotation. 2. Place the transmission in an accident or overturn. Wheel Installation 1. MAINTENANCE Tires Wheel Removal 1. Loose nuts could cause a tire to specification. 76 Do not service axle nuts that all nuts are torqued to come off the ground. 4. Loosen the wheel nuts slightly. Remove the wheel. WARNING! Install the wheel nuts finger tight.
Owners Manual
Page 84
... engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in your area. Carburetor/Engine Idle RPM Adjustment If the engine idle speed is calibrated at the factory for optimal performance at altitudes ranging from your Polaris dealer for more efficient operation. Idle Adjuster 80 Lock the parking brake. 2. Optional jets, available from zero to lower RPM...
... engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in your area. Carburetor/Engine Idle RPM Adjustment If the engine idle speed is calibrated at the factory for optimal performance at altitudes ranging from your Polaris dealer for more efficient operation. Idle Adjuster 80 Lock the parking brake. 2. Optional jets, available from zero to lower RPM...
Owners Manual
Page 90
.... 8. Tighten the bolt and torque to the center of the headlight beam should be adjusted slightly upward or downward. Place the transmission in . The most intense part of the headlight and make the adjustment. 25 ft. (7.6 m) X X 2" (5 cm) 1. Start the engine. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to 60 in neutral. 3. MAINTENANCE Lights Headlight Beam Adjustment...
.... 8. Tighten the bolt and torque to the center of the headlight beam should be adjusted slightly upward or downward. Place the transmission in . The most intense part of the headlight and make the adjustment. 25 ft. (7.6 m) X X 2" (5 cm) 1. Start the engine. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to 60 in neutral. 3. MAINTENANCE Lights Headlight Beam Adjustment...
Owners Manual
Page 91
... the lamp. 1. Hot components can result in reduced visibility when driving. Tip: The bulb must be positioned so the harness installs into the headlight housing and rotate clockwise firmly. MAINTENANCE Lights Poor lighting can cause burns to skin. Oil from the back of the headlight. 87 Allow lamps to remove the bulb. 3. Install the replacement bulb into the lamp at the bottom. 4.
... the lamp. 1. Hot components can result in reduced visibility when driving. Tip: The bulb must be positioned so the harness installs into the headlight housing and rotate clockwise firmly. MAINTENANCE Lights Poor lighting can cause burns to skin. Oil from the back of the headlight. 87 Allow lamps to remove the bulb. 3. Install the replacement bulb into the lamp at the bottom. 4.
Owners Manual
Page 107
... cloths and pads for a while to purchase a replacement. The water may have entered the engine or exhaust system. Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Electrical components/wiring • Radiator • Switches and controls • Transmission seals • Cab and body panels • Brakes • Labels and decals If an informational or graphic label becomes illegible or comes off, contact your Polaris vehicle. MAINTENANCE Cleaning...
... cloths and pads for a while to purchase a replacement. The water may have entered the engine or exhaust system. Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Electrical components/wiring • Radiator • Switches and controls • Transmission seals • Cab and body panels • Brakes • Labels and decals If an informational or graphic label becomes illegible or comes off, contact your Polaris vehicle. MAINTENANCE Cleaning...
Owners Manual
Page 110
... the spark plug cap. Tip: Use a section of gasoline. 8. Apply dielectric grease to specification. 5. Turn the engine over several times using the electric start. See page 105. 2. MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. To eliminate any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Treat the fuel system with the pre-measured amount of engine oil into...
... the spark plug cap. Tip: Use a section of gasoline. 8. Apply dielectric grease to specification. 5. Turn the engine over several times using the electric start. See page 105. 2. MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. To eliminate any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Treat the fuel system with the pre-measured amount of engine oil into...
Owners Manual
Page 114
... (if equipped). RPM/low ground speed Utility use low range (if equipped) more flexible and prevent belt burning. position Belt slippage from a stopped control and vehicle overturn. Poor engine performance Check for fouled plugs or foreign material in mud or snow Shift the transmission to low range (if equipped). The belt will become more frequently. WARNING! See your Polaris dealer. Inspect clutch seals for or snow...
... (if equipped). RPM/low ground speed Utility use low range (if equipped) more flexible and prevent belt burning. position Belt slippage from a stopped control and vehicle overturn. Poor engine performance Check for fouled plugs or foreign material in mud or snow Shift the transmission to low range (if equipped). The belt will become more frequently. WARNING! See your Polaris dealer. Inspect clutch seals for or snow...
Owners Manual
Page 118
SPECIFICATIONS Scrambler 500 4X4 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Demand Drive Fluid Capacity Coolant Rear Rack Capacity (Accessory) Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing Idle RPM ...
SPECIFICATIONS Scrambler 500 4X4 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Demand Drive Fluid Capacity Coolant Rear Rack Capacity (Accessory) Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing Idle RPM ...
Owners Manual
Page 124
... Warranty Registration form to perform warranty service. Should your original selling dealer; Damage resulting from state to you use any warranty issues. Some states do not allow limitations on how long an implied warranty lasts, so the above terms are in accordance with controlling state law. Engine Oil 1. SPARK ARRESTOR Polaris warrants that you if inconsistent with Polaris recommendations. 120 This warranty gives you specific...
... Warranty Registration form to perform warranty service. Should your original selling dealer; Damage resulting from state to you use any warranty issues. Some states do not allow limitations on how long an implied warranty lasts, so the above terms are in accordance with controlling state law. Engine Oil 1. SPARK ARRESTOR Polaris warrants that you if inconsistent with Polaris recommendations. 120 This warranty gives you specific...
Owners Manual
Page 127
.... This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it to fail to the Polaris standard limited warranty for evaporative emissions Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to control emissions. For exhaust emissions, emission...
.... This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it to fail to the Polaris standard limited warranty for evaporative emissions Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to control emissions. For exhaust emissions, emission...
Owners Manual
Page 131
... Adjustment ...80 Cargo...54-55 Caster Adjustment...73 Choke ...34 Chrome Wheel Care ...104 Cleaning and Storage ...102-107 Clothing ...9 Clutching Chart...115 Consumer Product Safety ...7 Coolant Bottle ...84 Coolant, Radiator ...85 Cooling System...84-85 Corrosion Removal, Chrome ...104 Crankcase Emission Control System 56 F Fluid, Brake ...32-33 Fluid, Demand Drive ...70 Foot Brake, Auxiliary ...31 Front Gearcase Fluid...70 Fuel Filter ...34 Fuel Safety ...11 Fuel Tank Cap...34 Fuel Valve...34 127
... Adjustment ...80 Cargo...54-55 Caster Adjustment...73 Choke ...34 Chrome Wheel Care ...104 Cleaning and Storage ...102-107 Clothing ...9 Clutching Chart...115 Consumer Product Safety ...7 Coolant Bottle ...84 Coolant, Radiator ...85 Cooling System...84-85 Corrosion Removal, Chrome ...104 Crankcase Emission Control System 56 F Fluid, Brake ...32-33 Fluid, Demand Drive ...70 Foot Brake, Auxiliary ...31 Front Gearcase Fluid...70 Fuel Filter ...34 Fuel Safety ...11 Fuel Tank Cap...34 Fuel Valve...34 127
Owners Manual
Page 132
INDEX G Gasoline Handling ...11 Gear Selector ...35 Gloves ...9 O Oil, Engine...63-64 Oil, Transmission...68-69 Oil and Filter Change ...65-67 Oil Level, Engine...64 Oil Pump Priming ...67 Oil Recommendations ...63 Operation on Public Lands ...56 Override Switch...26 H Handlebar Adjustment ...74 Hauling Cargo ...54-55 Headlamp Replacement ...87 Headlight Beam Adjustment ...86 Headlight Switch ...27 Helmet ...8 P Parking Brake ...30 Parking on an Incline...53 Periodic Maintenance Chart ...57-60 Polaris Product List...
INDEX G Gasoline Handling ...11 Gear Selector ...35 Gloves ...9 O Oil, Engine...63-64 Oil, Transmission...68-69 Oil and Filter Change ...65-67 Oil Level, Engine...64 Oil Pump Priming ...67 Oil Recommendations ...63 Operation on Public Lands ...56 Override Switch...26 H Handlebar Adjustment ...74 Hauling Cargo ...54-55 Headlamp Replacement ...87 Headlight Beam Adjustment ...86 Headlight Switch ...27 Helmet ...8 P Parking Brake ...30 Parking on an Incline...53 Periodic Maintenance Chart ...57-60 Polaris Product List...