Polaris SCRAMBER 500 User Manual

7SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your ATV. Your safety is involved when these wordsand

97MAINTENANCEBatteryYour ATV may have either a sealed battery, which requires littlemaintenance, or a conventional battery. A sealed battery can beide

98MAINTENANCEBatteryWARNINGImproperly connecting or disconnecting battery cables can resultin an explosion and cause serious injury or death. Whenremo

99MAINTENANCEBatteryBattery In stallatio nUsing a new battery that has not been fully charged can damage thebattery and result in a shorter life. It c

100MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more,remove the battery from the vehicle, ensure

101MAINTENANCEBatteryBattery Fluid (Conventional Battery)A poorly maintained battery willdeteriorate rapidly. Check the batteryfluid level often. Main

102MAINTENANCEBatteryBattery Charging (Sealed Battery)The following battery charging instructions apply only t o theinstallation of a sealed battery.

103MAINTENANCEBatteryBattery Charging (Sealed Battery)NOTE: Always verify battery condition before and 1-2 hours after theend of charging.State ofChar

104MAINTENANCECleaning and StorageSee page 113 for the part numbers of Polaris products.Washing t h e VehicleKeeping your ATV clean will not only impr

105MAINTENANCECleaning and StorageWashing t h e VehicleIf a high pressure water system is used for cleaning (notrecommended), exercise extreme caution

106MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion,preserve wheel life and

8SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow theseinstructions and procedures, which are outlined in further d

107MAINTENANCECleaning and StorageStorage TipsSee page 113 for the part numbers of Polaris products.CAUTIONStarting the engine during the storage peri

108MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect the fluid levels. Add or change fluids as recommended in thePeriodic Maintenance Cha

109MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recommendedin the Peri

110SPECIFICATIONS2007 Scrambler 500 4X4CapacitiesBody Style Gen IIIGross Vehicle Weight 845 lbs. (383 kg)Fuel 3.5 gal. (13.2 l)Transmission Oil 32 oz.

111SPECIFICATIONS2007 Scrambler 500 4X4Drive SystemDrive System Type PVTShift Type Side Lever (F-N-R)Gear Reduction - Reverse 4.74/1Gear Reduction - F

112SPECIFICATIONS2007 Scrambler 500 4X4Jetting ChartAltitude AMBIENTTEMPERATUREBelow 40° F(Below 5° C)+40°F and above(+5°C and above)Meters(Feet)0-180

113POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.

114TROUBLESHOOTINGContact your P olaris dealer for service if you’re unable to identifysolutions using the following charts.Drive Belt and Cover Probl

115TROUBLESHOOTINGEngine Doesn’t Turn OverPossible Cause SolutionTripped circuit breaker Reset the breakerLow battery voltage Recharge battery to 12.8

116TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

9SAFETYOperator SafetyS Always have the ATV inspected by an authorized Polaris dealer ifit’s been involved in an accident.S Never operate on hills too

117TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line Ins

118WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina,MN 55340, gives a SIX MONTH LIMITEDWARRANTY on all components of the Polaris Al

119WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIEDWARR

120WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

121WARRANTYU.S.A. EPA Emissions Limited W arrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limitedwarranty is in add

122MAINTENANCE LOGUse the following chart to record periodic maintenance.DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

123MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

124

125INDEXAAge Restrictions 6...Air Filter 90...All Wheel Drive 41-42...Auxiliary Brake 37, 77...AWD 4

126INDEXNNoise Emission Control System 61...OOil Change 69-71...Oil Filter Change 71...Oil Pump Priming 71...Oil,

10SAFETYOperator SafetyS Wet brakes may have reduced stopping ability. Test your brakes afterleaving water. If necessary, apply them lightly several t

11SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CANHAPPENThe risk of an accident is greatly increased

12SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDCarrying a passenger on anATV.WHAT CANHAPPENCarrying a passengergreatly reduces theoperator’s ability to

13SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV onpublic streets, roads orhighways.WHAT CANHAPPENThe ATV could collidewith another ve

14SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV after consumingalcohol or drugs.WHAT CANHAPPENConsumption of alcohol and/or drugscould

15SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDAttempting wheelies, jumpsand other stunts.WHAT CANHAPPENAttempting stunts increasesthe chance of an acc

16SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDRemoving hands from the handlebars or feet from the footrestsduring operation.WHAT CANHAPPENRemoving eve

17SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to use extracaution when operating onexcessively rough,slippery or loose terrain.WHAT CANHAPPENO

18SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating on excessively steep hills.WHAT CANHAPPENThe vehicle may overturn.HOW TO AVOID THEHAZARDNever

19SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDT raveling downhillimproperly.WHAT CANHAPPENImproperly descending a hillcould cause loss of controlor ov

20SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly crossing hills andturning on hills.WHAT CANHAPPENImproperly crossing orturning as hills could

21SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwardsor improperly dismountingwhile climbing a hill.WHAT CANHAPPENThe vehicle coul

22SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CANHAPPENOperating over obstacles could cause loss of control o

23SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CANHAPPENT ires may float, causing loss of tra

24SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CANHAPPENImproper installation of accessories or modi

25SAFETYOperator SafetyWARNINGLeaving the keys in the ignition can lead to unauthorized use ofthe vehicle resulting in serious injury or death. Always

26SAFETYFuel SafetyWARNINGGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gasol

A card containing important ATV safety information should be attachedto the owner’s manual on the next page. If you cannot locate this card,or if it h

1227SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Readand follow the instructions of the decals on

4328SAFETYSafety Decals and LocationsReverse Override Warning (3)WARNINGPushing reverse override button may cause sudden increases in power andtractio

57629SAFETYSafety Decals and LocationsNo Passenger Warning (5)WARNINGNEVER ride as a passenger.Passengers can cause aloss of control, resulting inSEVE

30SAFETYSafe Riding GearAlways wear clothing suited to t he type of riding. ATV riding requiresspecial protective clothing for comfort and to reduce t

31FEATURES AND CONTROLSElectrical SwitchesWARNINGActivating the override switch while the throttle is open can causeloss of control, resulting in seve

32FEATURES AND CONTROLSLight SwitchesWARNINGOperating the ATV on streets or roads, especially in darkness,could result in an accident and serious inju

33FEATURES AND CONTROLSThrottle LeverWARNINGDo not start or operate an ATV with sticking or improperlyoperating throttle controls, which could cause a

34FEATURES AND CONTROLSBrake LeverWARNINGOperating the ATV with a spongy brake lever can result in loss ofbraking, which could cause an accident. Neve

35FEATURES AND CONTROLSBrakesCheck the brake fluid level in themaster cylinder before each use ofthe ATV. The master cylinder (1) islocated on the lef

36FEATURES AND CONTROLSParking BrakeWARNINGOperating the ATV while the parking brake is engaged couldresult in an accident and serious injury or death

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of P olaris owners. We proudly produce an excitingline of util

37FEATURES AND CONTROLSAuxiliary BrakeWARNINGAggressively applying the rear brake when backing downhill maycause rear tipover , which could result in

38FEATURES AND CONTROLSChokeThe choke assists in starting a cold engine. Refer to the engine startingprocedure on page 45 for correct choke and thrott

39FEATURES AND CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector (1)is located on the right side of thevehicle.F: ForwardN: N

40FEATURES AND CONTROLSRecoil StarterIf the battery has been drained ordamaged and cannot start theengine, use of the recoil starter (1)will allow veh

41FEATURES AND CONTROLSAll Wheel Drive (AWD) SystemPolaris 4-wheel drive ATVs areequipped with a unique, Polarisexclusive, AWD system that’sactivated

42FEATURES AND CONTROLSAll Wheel Drive (AWD) SystemDisengaging Wheel HubsAlthough the hubs normally disengage when operating in reverse, oneor both hu

43OPERATIONBreak-In PeriodThe break-in period for your new Polaris ATV is the first ten hours ofoperation, or the time it takes to use the first two f

44OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injuryor death could result. Always inspect the vehicl

45OPERATIONStarting the EngineWARNINGEngine exhaust contains poisonous carbon monoxide and cancause loss of consciousness resulting in severe injury o

46OPERATIONStarting the Engine7. Move the engine stop switch to RUN.NOTE: Do not press the throttle while starting the engine.8. Turn the ignition key

2Copyright 2006 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

47OPERATIONDriving SafelyDriving Procedu res1. Sit upright with both feet on the footrests and both hands on thehandlebars.2. Start the engine and all

48OPERATIONDriving SafelyHauling CargoAccessory racks and hitches are available from your Polaris dealer.Always read and understand the load distribut

49OPERATIONDriving SafelyHauling CargoWARNINGHauling cargo improperly can alter vehicle handling and maycause loss of control or brake instability and

50OPERATIONDriving SafelyMaking Tu rnsYour Polaris ATV is equipped with a solid rear axle, which drives bothrear wheels equally at all times. This mea

51OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel,or during freezing weathe

52OPERATIONDriving SafelySidehillingWARNINGImproperly crossing hills or turning on hills can result in loss ofcontrol or vehicle overturn, resulting i

53OPERATIONDriving SafelyDriving UphillWARNINGBraking and handling are greatly affected when operating in hillyterrain. Improper procedure could cause

54OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25_

55OPERATIONDriving SafelyDriving DownhillWhenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to

8’ (2.4 m)56OPERATIONDriving SafelyTurning Around on a HillIf the vehicle stalls while climbing a hill, never back it down the hill!Use the K-turn to

3TABLE OF CONTENTSVEHICLE IDENTIFICATION NUMBERS 5...SAFETY 6...FEATURES AND CONTROLS 31...OPERATION 4

57OPERATIONDriving SafelyDriving Through WaterYour ATV can operate through waterwith a maximum recommendeddepth equal to the bottom ofthe footrests (1

58OPERATIONDriving SafelyDriving Over ObstaclesBe alert! Look ahead and learn to read the terrain you’re traveling on.Be constantly alert for hazards

59OPERATIONDriving SafelyDriving in ReverseFollow these precautionswhen operating in reverse:1. Always avoid backingdownhill.2. Back slowly.3. When in

60OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline if possible. If it’s unavoidable, followthese precautions:1. Turn the engine of

61EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, i ntake or exhaust components, as doing somay affect compliance with

62MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adj

63MAINTENANCEPeriodic Maintenance ChartMaintenance Chart Key" Perform these procedures more frequently for vehicles subjected tosevere use.E Emis

64MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"JBrake pad wear 10 H Month

65MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"Cooling hoses(if applicabl

66MAINTENANCELubrication RecommendationsCheck and lubricate all components at the intervals outlined in thePeriodic Maintenance Chart beginning on pag

4

67MAINTENANCELubrication Recommendations(1)(3)(2)(7)(6)(4)(5)4 or 8 o’clockposition- (end view)(8)

68MAINTENANCEEngine OilAlways check and change the engine oil at the intervals outlined in thePeriodic Maintenance Chart beginning on page 62. Always

69MAINTENANCEEngine OilOil and Filter ChangeCAUTIONContact with hot oil may result in serious burns. Do not allow hotoil to come into contact with ski

70MAINTENANCEEngine OilOil and Filter Change9. Place shop towels beneath the oil filter. Using an oil filter wrench,turn the filter (1) counterclockwi

71MAINTENANCEEngine OilOil and Filter ChangeOil Pump PrimingThis priming procedure must beperformed whenever the oil hoseconnection between the oil ta

72MAINTENANCETransmission OilAlways check and change the transmission oil at the intervals outlinedin the Periodic Maintenance Chart beginning on page

73MAINTENANCEFront Gearcase OilOil CheckAlways check and change the front gearcase oil at the intervalsoutlined in the Periodic Maintenance Chart begi

74MAINTENANCEDrive ChainPolaris ATV drive chains are equipped with o-ring-sealed, permanentlygreased pins and rollers. However, the outer surfaces of

75MAINTENANCEToe AlignmentWARNINGSevere injury or death can result from improper toe alignment andadjustment. Do not attempt to adjust tie rod alignme

76MAINTENANCEBrakesThe front and rear brakes are hydraulic disc brakes, activated bymoving the single brake lever toward the handlebar. These brakes a

5VEHICLE IDENTIFICATION NUMBERSRecord your ATV’s identification numbers and key number in thespaces provided. Remove the spare key and store it in a s

77MAINTENANCEBrakes1. Check the brake system for fluid leaks.2. Check the brakes for excessive travel orspongy feel.3. Check the friction pads for wea

78MAINTENANCESteering AssemblyThe steering assembly of the ATV should be checked periodically forloose nuts and bolts. If l oose nuts and bolts are fo

79MAINTENANCEHandlebarsWARNINGImproper adjustment of the handlebars or incorrect torquing ofthe adjuster block tightening bolts can cause limited stee

80MAINTENANCECarburetorIMPORTANT: Your Polaris ATV is calibrated at the fact ory foroptimal performance at altitudes ranging from zero to 6,000 feet (

81MAINTENANCEWheelsWARNINGOperating your ATV with worn tires, improperly inflated tires,non-standard tires or improperly installed tires will affect v

82MAINTENANCEWheelsWheel Installation1. Place the transmission in gear and lock the parking brake.WARNINGImproperly installed wheels can adversely aff

83MAINTENANCEWheelsFront Wheel Hub TighteningFront wheel bearing tightness and spindle nut retention are criticalcomponent operations. All service mus

84MAINTENANCERear Drive Chain SlackCAUTIONAdjusting or operating the ATV with improper rear drive chainslack can result in severe damage to the transm

85MAINTENANCERear Drive Chain Slack6. Roll the ATV forward or backwardto adjust the chain slack to theproper tension. See the illustrationfor proper s

86MAINTENANCEEngine Cooling SystemCoolant LevelThe recovery bottle (1) is locatedon the left side of the machine.The fluid level must be maintainedbet

6SAFETYOperator SafetyWARNINGFailure to follow the warnings contained in this manual can resultin serious injury or death.A Polaris ATV is not a toy a

87MAINTENANCEEngine Cooling SystemWARNINGEscaping steam can cause severe burns. Never remove thepressure cap while the engine is warm or hot. Always a

88MAINTENANCELightsWhen servicing a halogen lamp, don’t touch the lamp with barefingers. Oil from your skin leaves a residue, causing a hot spot thatw

89MAINTENANCELightsTaillig ht/Brakelight Lamp ReplacementIf the taillight/brakelight does not work the lamp m ay need to bereplaced.1. Remove the tail

90MAINTENANCEFilter SystemsAir Filter Service1. Remove the seat, releasethe clips, and remove theair box cover.2. Loosen the clamp and removethe filte

91MAINTENANCESpark PlugsSpark Plug RecommendationsCAUTIONUsing non-recommended spark plugs can result in serious enginedamage. Always use Polaris-reco

92MAINTENANCESpark PlugsSpark Plug Insp ectio nNormal PlugThe normal insulator tip is gray, tan or light brown. There will be fewcombustion deposits.

93MAINTENANCEVehicle ImmersionCAUTIONIf your vehicle becomes immersed, major engine damage canresult if the machine is not thoroughly inspected. Take

94MAINTENANCEPVT SystemThe basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As engine speed incr

95MAINTENANCEPVT SystemWARNINGFailure to comply with the instructions in this warning can result insevere injury or death.Do not modify any component

96MAINTENANCESpark ArrestorWARNINGFailure to heed the following warnings while servicing the sparkarrestor could result in serious injury or death.Do