Polaris Scrambler 9921777 User Manual

7SAFETYSafety TrainingATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized

97MAINTENANCEPVT SystemPVT DryingThere may be some instances when water is accidently ingested into the PVT system. Use the following instructions to

98MAINTENANCEBatteryImproperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing

99MAINTENANCEBatteryBattery Removal1. Place the transmission in gear.2. Lock the parking brake.3. Disconnect the battery hold-down strap.4. Remove the

100MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It

101MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure

102MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electrol

103MAINTENANCEBatteryBattery Charging (Sealed Battery)Always verify battery condition before and 1-2 hours after the end of charging.State of ChargeVo

104MAINTENANCECleaning and StorageWashing the VehicleKeeping your Polaris vehicle clean will not only improve its appearance but it can also extend th

105MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

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

8SAFETYSafe Riding GearAlways wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.He

107MAINTENANCECleaning and StorageStorage TipsNOTICE: Starting the engine during the storage period will disturb the protective film created by foggin

108MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beg

109MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Per

110MAINTENANCETransporting the VehicleFollow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in gear.3. Lo

111POLARIS PRODUCTSPart # DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt

112TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionStarting out going up a steep inclineUse low range (if equipped) or turn around using the

113TROUBLESHOOTINGEngine Doesn't Turn OverEngine Turns Over, Fails to StartEngine BackfiresPossible Cause SolutionTripped circuit breaker Reset t

114TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

115TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line Ins

116SPECIFICAT IONS* Based on EU Directive 76/432/ECScrambler 500 4X4Maximum Weight Capacity 275 lbs. (125 kg) (includes weight of opera-tor, cargo and

9SAFETYSafe Riding GearEye ProtectionDo not depend on eyeglasses or sunglasses for eye protection. When-ever riding a Polaris vehicle, always wear sha

117SPECIFICATIONSJetting ChartClutching ChartScrambler 500 4X4Driving System Type Automatic PVT (Polaris Variable Transmission)Shift Type Side Lever (

118WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris

119WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

120WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE) ARE L

121WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

122WARRANTYExported VehiclesHow to Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen outside of th

123WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in add

124MAINTENANCE LOGPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

125MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

126INDEXAAir Filter . . . . . . . . . . . . . . . . . . . . . 80All Wheel Drive Switch. . . . . . . . . . 27All Wheel Drive System . . . . . . .

10SAFETYSafety WarningsFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serio

127INDEXHHandlebar Adjustment . . . . . . . . . . . 76Hauling Cargo. . . . . . . . . . . . . . . 56-57Headlamp Replacement . . . . . . . . . . 89

128INDEXTThrottle Cable Freeplay . . . . . . . . . . 75Throttle Lever . . . . . . . . . . . . . . . . . 28Tire Tread Depth . . . . . . . . . . .

11SAFETYSafety WarningsHandling GasolineGasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution wheneve

12SAFETYSafety WarningsProtective ApparelRiding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a seri

13SAFETYSafety WarningsOperating on PavementOperating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely

14SAFETYSafety WarningsPhysical Control of the ATVRemoving a hand from the handlebars or feet from the footrests during operation can reduce your abil

15SAFETYSafety WarningsDescending Hills ImproperlyImproperly descending a hill could cause loss of control or overturn.• Always follow proper procedur

16SAFETYSafety WarningsStalling While Climbing a HillStalling, rolling backwards or improperly dismounting while climbing a hill could cause an overtu

WARNINGImproper vehicle use can result in SEVERE INJURY or DEATH.NEVER operate:S without proper training or instruction.S at speeds too fast for your

17SAFETYSafety WarningsOperating on Slippery TerrainFailure to use extra caution when operating on excessively rough, slippery or loose terrain could

18SAFETYSafety WarningsOperating Improperly in ReverseImproperly operating in reverse could result in a collision with an obstacle or person. Always f

19SAFETYSafety WarningsOperating Over ObstaclesImproperly operating over obstacles could cause loss of control or overturn.Before operating in a new a

20SAFETYSafety WarningsImproper Cargo LoadingOverloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause

21SAFETYSafety WarningsOperating a Damaged ATVOperating a damaged ATV can result in an accident. After any overturn or accident, have a qualified serv

22SAFETYSafety Labels and LocationsWarning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label

23SAFETYSafety Labels and LocationsDiscretionary WarningWARNING• Never operate this ATV on HILLS steeper than 25 degrees 25°. To pre-vent overturn o

24SAFETYSafety Labels and Locations“No Passenger” WarningWARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE

25SAFETYSafety Labels and LocationsAge 16 WarningWARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or de

26FEATURES AND CONTROLSSwitchesOverride SwitchThis vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backi

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or

27FEATURES AND CONTROLSSwitchesHeadlight SwitchUse the headlight switch to turn the lights on and off and to change the lights from high beam to low b

28FEATURES AND CONTROLSThrottle LeverOperating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or

29FEATURES AND CONTROLSBrake LeverOperating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never oper

30FEATURES AND CONTROLSParking BrakeLocking the Parking Brake1. Place the transmission in gear.2. Squeeze and release the brake lever two or three tim

31FEATURES AND CONTROLSAuxiliary Foot BrakeAggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could resu

32FEATURES AND CONTROLSBrake FluidAn over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brak

33FEATURES AND CONTROLSBrake FluidHand BrakeCheck the brake fluid level in the master cylinder before each use of the vehicle. The master cylinder is

34FEATURES AND CONTROLSChokeThe choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 for correct choke and throt

35FEATURES AND CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector is located on the right side of the vehicle. F: Forward Gear

36FEATURES AND CONTROLSAll Wheel Drive (AWD) SystemThe All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is i

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of uti

37FEATURES AND CONTROLSAll Wheel Drive (AWD) SystemDisengaging AWDAlthough the hubs normally disengage when operating in reverse, one or both hubs may

38OPERATIONFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or

39OPERATIONBreak-In PeriodEngine and Drivetrain Break-in1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever han

40OPERATIONSafe Operation Practices1. Complete the recommended safety training before operating this vehicle. See page 7.2. Do not allow anyone under

41OPERATIONKnow Your Riding Area/Tread LightlyFamiliarize yourself with all laws and regulations concerning the opera-tion of this off-road vehicle in

42OPERATIONPre-Ride ChecklistFailure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accid

43OPERATIONStarting the Engine1. Position the vehicle on a level surface outdoors or in a well-venti-lated area. 2. Place the transmission in neutral.

44OPERATIONStarting the Engine9. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds,

45OPERATIONDriving Procedures1. Wear a helmet and eye protection. See page 8.2. Sit upright with both feet on the footrests and both hands on the hand

46OPERATIONTurning the VehicleYour ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the whe

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2008 Polaris Sales Inc. All information contained with

47OPERATIONDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow the

48OPERATIONDriving UphillBraking and handling are greatly affected when operating in hilly ter-rain. Improper procedure could cause loss of control or

49OPERATIONDriving on a Sidehill (Sidehilling)Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Av

50OPERATIONDriving DownhillWhen driving downhill, follow these precautions:1. Avoid steep hills (25° maximum).2. Shift body weight uphill.3. Drive str

51OPERATIONTurning Around on a Hill (K-Turn)If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.1.

52OPERATIONDriving Through WaterYour ATV can operate through water with a maxi-mum recommended depth equal to the bottom of the footrests. Follow thes

53OPERATIONDriving Over ObstaclesFollow these precautions when operating over obstacles:1. Always check for obstacles before operating in a new area.2

54OPERATIONDriving in ReverseFollow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.2. Always a

55OPERATIONParking on an InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Plac

56OPERATIONHauling CargoOverloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or bra

3TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . .

57OPERATIONHauling CargoNever exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual.C

58EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

59MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, ad

60MAINTENANCEPeriodic Maintenance ChartImproperly performing the procedures marked with a  could result in component failure and cause an accident, w

61MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.Item Maintenance Interval(whichever com

62MAINTENANCEPeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related ServiceQ Have an

63MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)Exhaust muffler/ pipe100 H 12 M

64MAINTENANCELubrication GuideCheck and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 59. It

65MAINTENANCELubrication GuideFront Prop Shaft YokeSwing Arm BushingsTie Rod EndsFront HubsBall JointAxle Housing4 or 8 o'clockposition (end view

66MAINTENANCEEngine OilOil RecommendationsPolaris recommends the use of Polaris PS-4 PLUS Performance Syn-thetic 2W-50 4-cycle oil or a similar oil fo

4INTRODUCTIONThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sy

67MAINTENANCEOil and Filter ChangeAlways change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. A

68MAINTENANCEOil and Filter Change8. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it.9. L

69MAINTENANCEOil and Filter ChangeOil Pump PrimingThis priming procedure must be performed whenever the oil hose connection between the oil tank and p

70MAINTENANCETransmission OilAlways check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on pag

71MAINTENANCETransmission OilOil Change1. Position the vehicle on a level surface.2. Remove the propshaft shield from the right side of the vehicle to

72MAINTENANCEFront Gearcase FluidAlways check and change the front gearcase fluid at the intervals out-lined in the Periodic Maintenance Chart beginni

73MAINTENANCEBrakesThe front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The auxiliary

74MAINTENANCEToe AlignmentUse the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4&quo

75MAINTENANCESteering AssemblyThe steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are fo

76MAINTENANCEHandlebarsThe handlebars can be adjusted for rider preference.WARNING! Improper adjustment of the handlebars or incorrect torquing of the

5INTRODUCTIONFailure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a

77MAINTENANCETiresOperating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle

78MAINTENANCETiresWheel Removal1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake.2. Loosen the wheel

79MAINTENANCETiresWheel Nut Torque SpecificationsCheck the wheel nut torques occasionally and when they've been loos-ened for service. Item Torqu

80MAINTENANCEAir Filter1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake.2. Remove the seat.3. Releas

81MAINTENANCEBreather Filter1. Remove the clamps and pull the breather filter out of the hoses. It's not necessary to remove the lower hose from

82MAINTENANCECarburetorYour Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and

83MAINTENANCEDrive ChainDrive Chain LubricationPolaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However

84MAINTENANCEDrive ChainRear Drive Chain SlackCheck the amount of chain slack in three different locations by moving the vehicle slightly forward to g

85MAINTENANCEDrive ChainRear Drive Chain Slack6. Roll the ATV forward or backward to adjust the chain slack to the proper tension. See the illustratio

86MAINTENANCECooling SystemThe engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recov

6INTRODUCTIONVehicle Identification NumbersRecord your vehicle's identification numbers and key number in the spaces provided. Remove the spare k

87MAINTENANCECooling SystemRadiator CoolantTo ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain t

88MAINTENANCELightsHeadlight Beam AdjustmentThe headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the ad

89MAINTENANCELightsPoor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. C

90MAINTENANCELightsTaillight/Brakelight Lamp Replacement1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set a

91MAINTENANCESpark PlugsSpark Plug RecommendationsRefer to the specifications section beginning on page 116 for the recom-mended spark plug type and g

92MAINTENANCESpark PlugsSpark Plug ConditionNormal Spark PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion deposi

93MAINTENANCEVehicle ImmersionIf your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the ve

94MAINTENANCESpark ArrestorFailure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never ru

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

96MAINTENANCEPVT SystemThe basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed inc