Polaris Scrambler 500 User Manual

UniversalOwner's ManualVehicle Maintenance and Safety2003ATVforRead this manual carefully. It contains important safety information.This is an ad

8SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your ATV. Your safety is involved when t hese wordsan

98MAINTENANCE AND LUBRICATIONLubrication RecommendationsEngine Oil CheckThe oil tank is located either on the left side of the vehicle (externaltank m

99MAINTENANCE AND LUBRICATIONEngine Cooling SystemCoolant LevelThe recovery bottle (1) is located onthe left side of the machine. Toaccess the recover

100MAINTENANCE AND LUBRICATIONEngine Cooling SystemRadiator Coolant LevelNOTE: This procedure is requiredonly if t he cooling system has beendrained f

101MAINTENANCE AND LUBRICATIONEngine Cooling SystemNOTE: To ensure that the coolant maintains its ability to protect theengine, we recommend that the

102MAINTENANCE AND LUBRICATIONAdjustmentsOil Pump - 250 Engines1. Before adjusting the oil pump, check theengine idle RPM and carburetor settingsin th

103MAINTENANCE AND LUBRICATIONAdjustmentsOil Pump - 400 Engines1. Before adjusting the oil pump, check engine idle RPM andcarburetor adjustments in yo

104MAINTENANCE AND LUBRICATIONAdjustmentsFront BrakeThe front brakes are hydraulic disc brakes. They’re activated bymoving the brake lever toward the

105MAINTENANCE AND LUBRICATIONAdjustmentsRear BrakeThe rear brake is a hydraulic discbrake. The rear brake system isself-adjusting and requires nomain

106MAINTENANCE AND LUBRICATIONAdjustmentsToe AlignmentUse the following procedure to check the toe alignment of the vehicle.The recommended toe alignm

107MAINTENANCE AND LUBRICATIONAdjustmentsSteering AssemblyThe steering assembly of the ATV should be checked periodically forloose nuts and bolts. If

9SAFETYOperator SafetyS Read this manual and all labels carefully, and follow the operatingprocedures described.S Never operate an ATV without proper

108MAINTENANCE AND LUBRICATIONAdjustmentsHandlebarsThe handlebars can be adjusted forrider preference.1. Locate handlebar bolts (1). Onmodels with a h

109MAINTENANCE AND LUBRICATIONAdjustmentsCarburetorIMPORTANT: Your Polaris ATV is calibrated at the factory foroptimal performance at altitudes rangin

110MAINTENANCE AND LUBRICATIONAdjustmentsCarburetor4-Cycle EnginesIf the engine idle speed is not satisfactory,and all other conditions are favorable,

111MAINTENANCE AND LUBRICATIONAdjustmentsSide Panel Removal - Gen IVNOTE: Side panel removal may be difficult until the locking tabs andreceivers have

112MAINTENANCE AND LUBRICATIONAdjustmentsWheel Removal1. Stop the engine, place the transmission in gear and lock theparking brake.2. Loosen the wheel

113MAINTENANCE AND LUBRICATIONAdjustmentsWheel Installatio n1. Place the transmission in gearand lock the parking brake.2. Place the wheel on the whee

114MAINTENANCE AND LUBRICATIONAdjustmentsFront Wheel Hub TighteningFront wheel bearing tightness and spindle nut retention are criticalcomponent opera

115MAINTENANCE AND LUBRICATIONAdjustmentsDrive ChainPolaris ATV drive chains are equipped with o-ring-sealed, permanentlygreased pins and rollers. How

116MAINTENANCE AND LUBRICATIONAdjustmentsRear Drive Chain Slack - Con centric Drive Mo delsCheck the amount of chain slack in three different location

117MAINTENANCE AND LUBRICATIONAdjustmentsRear Drive Chain Slack - Con centric Drive Mo dels6. Roll the ATV forward or backwardto adjust the chain slac

10SAFETYOperator SafetyS Always have the ATV inspected by an authorized Polaris dealer ifit’s been involved in an accident.S Never operate on hills to

118MAINTENANCE AND LUBRICATIONFilter SystemsAir F ilter Removal and Service - 2-Cycle Engines1. Remove the ATV seat.2. Release the clips securing the

119MAINTENANCE AND LUBRICATIONFilter SystemsAir Filter Service - 4-Cycle1. Remove the seat, release the clips,and remove the air box cover.2. Loosen t

120MAINTENANCE AND LUBRICATIONLightsWhen servicing a halogen lamp, don’t t ouch the lamp with barefingers. Oil from your skin leaves a residue, causin

121MAINTENANCE AND LUBRICATIONLightsHeadlight Lamp Replacement - Trail Blazer1. Remove the front cover and unplug the light harness.2. Remove the rubb

122MAINTENANCE AND LUBRICATIONLightsHeadlight Lamp Replacement - Gen IV1. Remove the three screws on the headlight pod.2. Using a small flat-blade scr

123MAINTENANCE AND LUBRICATIONLightsHigh Beam Adju stment - Gen IVThe headlight beam can be adjusted to any position desired by turningthe adjusting k

124MAINTENANCE AND LUBRICATIONLightsHeadlight Housing Replacement - Gen IV1. Remove the three screws on the headlight pod.2. Using a small flat-blade

125MAINTENANCE AND LUBRICATIONLightsTaillight/Brakelight Lamp ReplacementIf the taillight/brakelight does not work the lamp may need to bereplaced.1.

126MAINTENANCE AND LUBRICATIONSpark PlugsRefer to your owner’s manual supplement for recommended spark plugand gap specifications.Spark plug condition

127MAINTENANCE AND LUBRICATIONVehicle ImmersionIf it’s impossible to take your ATV to a dealer before starting it, followthe steps outlined below.1. M

11SAFETYOperator SafetyS Wet brakes may have reduced stopping ability. Test your brakes afterleaving water. If necessary, apply them lightly several t

128MAINTENANCE AND LUBRICATIONSpark ArrestorWARNINGFailure to heed the following warnings while servicing the sparkarrestor could result in serious in

129MAINTENANCE AND LUBRICATIONSpark Arrestor1. Remove the arrestor clean-out plug(s) (1) from the bottom of themuffler.2. Place the transmission in ne

130MAINTENANCE AND LUBRICATIONRecoil HousingTo prevent possible engine damage, always drain the recoil housingafter operating the ATV in very wet cond

131MAINTENANCE AND LUBRICATIONPVT SystemThe basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As

132MAINTENANCE AND LUBRICATIONPVT SystemPVT DryingThere may be some instances when water is accidently ingested intothe P VT system. Use the following

133MAINTENANCE AND LUBRICATIONBattery (Conventional)Keep the battery terminals and connections free of corrosion. Ifcleaning is necessary, remove the

134MAINTENANCE AND LUBRICATIONBatteryReplenishing Battery Fluid (Conventional Battery)A poorly maintained battery willdeteriorate rapidly. Check the b

135MAINTENANCE AND LUBRICATIONBatteryBattery Installation1. Set the battery in the battery holder.2. With conventional batteries, install the battery

136MAINTENANCE AND LUBRICATIONBatteryBattery Charging (Sealed Battery)For a refresh charge, follow all instructions carefully.1. Check the battery vol

137MAINTENANCE AND LUBRICATIONCleaning and StorageSee page 141 for the part numbers of Polaris-recommended products.Cleaning the ATVKeeping your ATV c

12SAFETYOperator SafetyPOTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CANHAPPENThe risk of an accident is greatly increased if the

138MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsSee page 141 for the part numbers of Polaris-recommended products.Clean the ExteriorMake

139MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsSee page 141 for the part numbers of Polaris-recommended products.Fog the Engine2Cycle-

140MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsBattery StorageConventional Battery: Remove the battery and add distilled water tothe pr

141POLARIS RECOMMENDED PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871098 Premium 2-Cycle Engine Oil (qt.)2871721

142TROUBLESHOOTINGDrive Belt an d Cover ProblemsPossible Cause SolutionDriving the ATV onto apickup or tall trailer inhigh range.Shift transmission to

143TROUBLESHOOTINGContact your Polaris dealer for service if you’re unable to identifysolutions using the following charts.Engine Doesn’t Tu rn OverPo

144TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

145TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line Ins

146WARRANTYLIMITED WARRANTYPolaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives aSIX MONTH LIMITED WARRANTY on all components of thePolar

147WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

13SAFETYOperator SafetyPOTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CANHAPPENCarrying a passenger greatly reduces the operator’ s ability tobal

148WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITEDTO THE IMPLIED WARRANTIES OF MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE) ARE LIMI

149INDEXAAccessories 75...Adjustments 102-117...Age Restrictions 7...Air Filter

150INDEXOOil I njection Tank 45...Oil Pump Adjustment - 250 Engines 102...Oil Pump Adjustment - 400 Engines 103...Oil

Operate without proper training or instruction.Operate on public roads. A collision can occur with another vehicle.Operate at speeds too fast for you

14SAFETYOperator SafetyPOTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks,paths, parking lots, and driveways.WHAT CANHAPPENATV ti

15SAFETYOperator SafetyPOTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CANHAPPENThe ATV could collide with another vehicl

16SAFETYOperator SafetyPOTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eyeprotection and protective clothing.WHAT CANHAPPENOper

17SAFETYOperator SafetyPOTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CANHAPPENConsumption of alcohol and/or drugs could seri

WARNINGThe engine exhaust from thisproduct contains chemicals knownto cause cancer, birth defects orother reproductive harm.

18SAFETYOperator SafetyPOTENTIAL HAZARDAttempting wheelies, jumps and other stunts.WHAT CANHAPPENAttempting stunts increases the chance of an accident

19SAFETYOperator SafetyPOTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CANHAPPENPoor maintenance

20SAFETYOperator SafetyPOTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliarterrain.WHAT CANHAPPENUnfamiliar terrain may c

21SAFETYOperator SafetyPOTENTIAL HAZARDFailure to use extra caution when operating on excessivelyrough, slippery or loose terrain.WHAT CANHAPPENOperat

22SAFETYOperator SafetyPOTENTIAL HAZARDT urning improperly.WHAT CANHAPPENImproper turns could cause loss of control and lead to a collisionor overturn

23SAFETYOperator SafetyPOTENTIAL HAZARDClimbing hills improperly.WHAT CANHAPPENImproper hill climbing could cause loss of control or overturn.HOW TO A

24SAFETYOperator SafetyPOTENTIAL HAZARDT raveling downhill improperly.WHAT CANHAPPENImproperly descending a hill could cause loss of control orovertur

25SAFETYOperator SafetyPOTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CANHAPPENImproperly crossing or turning as hills could caus

26SAFETYOperator SafetyPOTENTIAL HAZARDStalling, rolling backwards orimproperly dismounting whileclimbing a hill.WHAT CANHAPPENThe vehicle could overt

27SAFETYOperator SafetyPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CANHAPPENOperating over obstacles could cause loss of control or overt

1We’ve created a web site just for YOU!S Technical tipsS New product introductionsS Event schedulesS Parts and Service Manual informationS Exciting de

28SAFETYOperator SafetyPOTENTIAL HAZARDOperating the ATV through deep or fast-flowing water .WHAT CANHAPPENT ires may float, causing loss of traction

29SAFETYOperator SafetyPOTENTIAL HAZARDOperating this ATV with improper tires, or with improper or uneventire pressure.WHAT CANHAPPENUse of improper t

30SAFETYOperator SafetyPOTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CANHAPPENOverloading and towing can cause changes

31SAFETYOperator SafetyAfter any overturn or accident, have a qualified service dealerinspect the entire vehicle for possible damage, including (but n

32SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection.Read and follow the instructions on each decal caref

33SAFETYSafety Decals and LocationsSee your Owner’s Manual Supplement for specifications.IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss ofcontro

34SAFETYSafety Decals and LocationsATTENTIONDOperation of thisvehicle without thefilter element will severelydamage the engine.DClean air filter often

35SAFETYSafety Decals and LocationsALL WHEELDRIVESWITCHDo not push switch toengage AW D if the rearwheels are spinning.This may cause severedrive shaf

36SAFETYSafe Riding GearAlways wear clothing suited to the type of riding. ATV riding requiresspecial protective clothing for comfort and to reduce th

37CONTROLSElectrical SwitchesActivating the override switch while the throttle is open can causeloss of control, resulting in severe injury or death.

2All information in this manual is based on the latest product data and specificationsavailable at the time of printing. Polaris Industries Inc. reser

38CONTROLSThrottle LeverEngine speed and vehiclemovement are controlled bypressing the throttle lever.The throttle lever (1) is springloaded. Engine s

39CONTROLSLight SwitchesThe light switch i s located on theleft handlebar (1). It’s used to turnthe lights on and off and to switchthe lights from HI

40CONTROLSBrake LeverThe front and rear brakes are appliedby squeezing the brake lever (1)toward the handlebar. The front andrear brakes are hydraulic

41CONTROLSParking BrakeSetting the Parking Brake1. Squeeze and release the brakelever (1) two or three times, thensqueeze and hold.2. Push the park br

42CONTROLSAuxiliary BrakeThe auxiliary brake (1), i slocated on the inside of the rightfloor board and is operated bythe right foot. The auxiliarybrak

43CONTROLSChokeThe choke assists in starting a cold engine. Refer to the engine startingprocedure on page 59 for correct choke and throttle settings d

44CONTROLSFuel SafetyGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gasoline.S

45CONTROLSOil Injection Tank - 2-Cycle Mod e lsModels with 2-cycle engines haveoil injection. The oil injection t ankfiller cap (1) is located on the

46CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector (1)is located on the right side of thevehicle. Shift patterns vary,depend

47CONTROLSRecoil StarterIf the battery is weak and cannotstart the engine, use of the recoilstarter (1) will allow vehicleoperation until repairs can

3WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of P olaris owners. We proudly produce an excitingline of util

48FEATURESAll Wheel Drive (AWD) SystemPolaris 4 wheel drive ATVs areequipped with a unique, Polarisexclusive, Demand 4 Drive (AWD)system that’s activa

49FEATURESAll Wheel Drive (AWD) SystemDisengaging Wheel HubsAlthough the hubs normally disengage when operating in reverse, oneor both hubs may occasi

50FEATURESIndicator LightsThe configuration of the indicator li ghts differs with individual models.Not every model is equipped with all of the lights

51FEATURESInstrument ClusterYour ATV is equipped with an instrument cluster that senses vehiclespeed from the right front wheel. The instrument cluste

52FEATURESInstrument ClusterRider Information CenterThe rider information center is located in the lower portion of theinstrument cluster.1. Gear Indi

53FEATURESInstrument ClusterRider Information CenterThe rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Tota

54FEATURESInstrument ClusterRider Information CenterMode 4 - Programmable Service IntervalThe purpose of the programmable service interval is to provi

55FEATURESInstrument ClusterRider Information CenterDiagnostic ModeThe diagnostic mode is for i nformational purposes only. P l ease returnyour ATV to

56OPERATIONBreak-In Period2-Cycle EnginesThe break-in period for your new Polaris ATV is defined as the time ittakes to use the first tank of fuel. No

57OPERATIONBreak-In Period4-Cycle EnginesThe break-in period for your new P olaris ATV is defined as the first tenhours of operation, or the time it t

4

58OPERATIONPre-Ride InspectionUse the following checklist to verify that your vehicle is in properworking condition before each use.Item/Inspection Pr

59OPERATIONStarting the EngineStarting a Cold Engine1. Place the transmission in neutraland lock the parking brake.2. Turn the fuel tank valve on.3. S

60OPERATIONStarting the EngineStarting a Warm EngineWarm engines do not normally require the use of the choke. Using thechoke can cause the spark plug

61OPERATIONHauling CargoYour ATV has been designed to carry or tow a certain amount of load.Always read and understand the load distribution warnings

62OPERATIONHauling CargoHauling cargo improperly can alter vehicle handling and may causeloss of control or brake instability and result in serious in

63OPERATIONDriving SafelyDriving Procedures1. Sit upright with both feet on the footrests and both hands on thehandlebars.2. Start the engine and allo

64OPERATIONDriving SafelyMaking Tu rnsSome Polaris ATVs are equipped with a solid rear axle, which drivesboth rear wheels equally at all times. This m

65OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel,or during freezing weathe

66OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow t heseprecautions:1. Always travel straight uphill.2. Avoid steep hills (25_

67OPERATIONDriving SafelySidehillingSidehilling can be a dangerous type of driving and should be avoided ifat all possible. If you do enter into a sit

5TABLE OF CONTENTSWELCOME 3...TABLE OF CONTENTS 5...VEHICLE IDENTIFICATION NUMBERS 6...SAFETY 7.

68OPERATIONDriving SafelyDriving DownhillWhenever descending a hill, follow t hese precautions:1. Proceed directly downhill.2. Transfer your weight to

69OPERATIONDriving SafelyTurning Around on a HillIf the vehicle stalls while climbing a hill, never back it down the hill!One maneuver that can be use

70OPERATIONDriving SafelyDriving Through WaterYour ATV can operate through waterwith a maximum recommendeddepth equal to the bottom ofthe footrests (1

71OPERATIONDriving SafelyDriving Over Ob staclesBe alert! Look ahead and learn to read the terrain you’re traveling on.Be constantly alert for hazards

72OPERATIONDriving SafelyDriving in ReverseFollow these precautions when operating in reverse:1. Always avoid backingdownhill.2. Back slowly.3. When i

73OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline if possible. If it’s unavoidable, followthese precautions:1. Turn the engine of

74NOISE EMISSION CONTROLSYSTEM REGULATIONTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or t he causing

75MAINTENANCE AND LUBRICATIONAccessoriesAuxiliary power outlets provide 12V power for operating accessoriessuch as hand held spot lights. Accessory ou

76MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleHours of operation are based on a 10 mph average. If service is due at20 hours, the equivale

77MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours/MilesFrequency RemarksTaillight/brakelight Pre-Ride Pre-Ride Check operation dail

6VEHICLE IDENTIFICATION NUMBERSThe vehicle frame vehicle identification number (VIN)(1) and engineserial number (2) are important for model identifica

78MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours/MilesFrequency RemarksCarburetor floatbowl50 hrs. 6 months Drain bowl periodicall

79MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours/MilesFrequency RemarksJLFuel system 100hours12 months Check for leaks at tankcap,

80MAINTENANCE AND LUBRICATIONLubrication RecommendationsNOTE: Hours are based on 10 m ph average. If service is due at 20hours, the equivalent odomete

81MAINTENANCE AND LUBRICATIONLubrication Recommendations(4)(1)(5)(2)(2)(3)

82MAINTENANCE AND LUBRICATIONLubrication RecommendationsItem Lube Method Frequency(6) Demand 4Hubs - AllWheel Drive ATVsPremiumHub LubeRemove set scre

83MAINTENANCE AND LUBRICATIONLubrication Recommendations(7)(9)(8)(6) 4 O’clockposition(6)(11)(10)(12)(14)(15)(13)(13)

84MAINTENANCE AND LUBRICATIONPeriodic Maintenan ce RecordUse the following chart to record periodic maintenance.MaintenanceIntervalPerformedServicingD

85MAINTENANCE AND LUBRICATIONLubrication RecommendationsPolaris 2-Cycle LubricantsPolaris Premium 2-cycle lubricants are the most advanced formulation

86MAINTENANCE AND LUBRICATIONLubrication RecommendationsPremium 4 Synthetic OilPolaris Premium 4 All Season Synthetic engine oil has been speciallyfor

87MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil and Filter Chang e4-Cycle Engines With External Oil Tank1. Position the vehicle on a level

7SAFETYOperator SafetyAge RestrictionsThis vehicle is an ADULT VEHICLE ONLY. Operation is prohibitedfor anyone under 16 years of age.Know Your V ehicl

88MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil and Filter Chang e4-Cycle Engines With External Oil Tank11. Lubricate the gasket on the ne

89MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil and Filter Chang eMagnum 330 2x4, Magnum 330 4x4, Trail Boss1. Position the vehicle on a l

90MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil and Filter Chang eMagnum 330 2x4, Magnum 330 4x4, Trail Boss12. Remove the dipstick and fi

91MAINTENANCE AND LUBRICATIONLubrication RecommendationsTransmission Oil Check - Models with F ill PlugScrambler 500 4x4, Magnums: 500, 330 4x4, 330 2

92MAINTENANCE AND LUBRICATIONLubrication RecommendationsTransmission Oil Change - Mode ls with Fill PlugScrambler 500 4x4, Magnums: 500, 330 4x4, 330

93MAINTENANCE AND LUBRICATIONLubrication RecommendationsTransmission Oil Check - Models with DipstickOn most 2x4 models, thetransmission dipstick (1)

94MAINTENANCE AND LUBRICATIONLubrication RecommendationsTransmission Oil Chan g e - 2x4 Mod els7. Tighten the jam nut securely while holding the adjus

95MAINTENANCE AND LUBRICATIONLubrication RecommendationsFront Gearcase Oil CheckThe front gearcase oil level should bechecked every six months or 1000

96MAINTENANCE AND LUBRICATIONLubrication RecommendationsRear Gearcase Oil CheckWith the ATV on a level surface,remove the fill plug and view theoil le

97MAINTENANCE AND LUBRICATIONLubrication RecommendationsCounter Balance Oil Check - 400 2-Cycle EnginesThe counter balance oil should be checked semi-