PolarisメーカーScrambler 500 4x4の使用説明書/サービス説明書
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A car d cont aining import ant A TV saf ety infor mat ion should be at tac hed to t he owner ’s manual on t he next page. If you c annot loc ate t his c ard, or if it has been rem oved, pleas e call 1-800- 342-3764 f or ass ist ance.
1 We’ve cr eated a Web sit e ju st f or you! S T echnical ti ps S New product introductions S Event schedules S Parts and Se rvice M anual information S Exciting details about The W ay Out Ch e c k it ou t.
2 Copyr ight 2003 Pol a ri s Sa l e s Inc . All inf or ma t i on c ont a i ne d wi t hi n t hi s publi c a t ion i s ba s e d on the l a t e s t pr oduc t i nf or ma t i on a t the t i me of publ i c a t i on.
3 WELC O ME Thank you f or purc hasing a Polar is vehic le, and we lcome to our wor ld-wide f amily of Polaris owne rs. W e proudly produc e an exciting line of utility a nd re cre ational produc ts.
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5 TABLE OF CONTE NTS WELCO ME 3 ................................. VEHICL E IDENTI FICA TION NUM BERS 6 ........ SAFET Y 7 ................................... FEA TURES AND CONTROLS 37 ............... OPE RA TION 49 .............................. EMI SSION CONTRO L SYSTEMS 68 .
6 VE HICLE IDENTIFICATION NUMBERS The vehic le fra me vehic le identific ation number (VIN) (1) and engine ser ial numbe r a re impor tant f or mode l i dentif ication w hen re gistering your ve hicle, when obta i ning insura nce, and whe n ordering replacem ent part s.
7 SA FETY Operator S afety Age Restr ictions This vehi cle is an ADUL T VEHICLE ONL Y . Operati on is prohi bited for anyone under 16 ye ars of age . Know Y our V e hicle As the opera tor of the vehicle , you are re sponsible for your persona l saf ety , the safe ty of others, and the prote ction of our environme nt.
8 SA FETY Operator S afety The f ollowing signal wor ds and symbols appe ar throughout this manua l and on your A TV . Y our safe ty is involved whe n t hese words and symbols ar e used. Beco me fa miliar w ith their mea nings befor e re ading the manua l.
9 SA FETY Operator S afety S Rea d this manual and a ll l ab els ca ref ully , and f ollow the ope rating proce dures desc ribed. S Neve r oper ate a n A TV without proper instr uction. T ake a training course . B eginners shoul d recei ve training from a certi fied ins tructo r .
10 SA FETY Operator S afety S Alway s have t he A TV i ns pected b y an aut hori zed P ol aris d ealer i f it ’ s b een invol ved in an accident . S Ne ver ope rate on hills too steep fo r the A TV or for your a bilities. Pra ctice o n smalle r hills befo re a ttempting lar ger hills.
11 SA FETY Operator S afety S W et bra kes may ha ve re duced stopping a bility . T est your br akes a fte r lea ving wate r . If ne cessa ry , apply the m lightly seve ra l times to allow frict io n to d ry out t he pad s. S Always che ck for obsta cles or people be hind the A TV bef ore oper at- in g in rev erse.
12 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV wit hout pr oper inst ruct ion. WHA T CAN H APPEN The r isk of an acc ident is great ly inc reased if t he operat or does not know how t o operat e the A T V pr operly in diff erent sit uations and on different t ypes of t errain.
13 SA FETY Operator S afety POTENTI AL HAZ ARD Carr ying a passenger on an A T V . WHA T CAN H APPEN Carr ying a passenger great ly reduc es the operat or ’s ability t o balance and cont rol t he A T V , which could c ause an accident and injury t o t he operat or and/ or pass enger .
14 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating an A T V on pav ed surf aces , inc luding sidewalks , paths , par king lot s, and driveway s.
15 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV on public st reet s, roads or highway s. WHA T CAN H APPEN The A T V c ould collide wit h another vehicle. HOW T O A VOID TH E HAZ ARD Never operat e the A T V on any public str eet, road or highway , including dirt and gr avel roads .
16 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A T V wit hout wearing an approv ed helmet , ey e prot ect ion and prot ect ive clot hing. WHA T CAN H APPEN Oper ating an A T V wit hout an approved helm et inc reases the ris k of a s evere head injur y or deat h in t he event of an accident .
17 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t he A T V af ter consum ing alcohol or dr ugs. WHA T CAN H APPEN Consumpt ion of alcohol and/ or drugs could ser iously aff ect operat or judgment . React ion ti me may be slower and oper ator balance and perc eption c ould be affect ed.
18 SA FETY Operator S afety POTENTI AL HAZ ARD At tem pting wheelies , jum ps and ot her st unt s. WHA T CAN H APPEN At tem pting s tunt s inc reases the c hance of an accident , including an overt urn. HOW T O A VOID TH E HAZ ARD Never att empt wheelies , jumps, or ot her stunt s.
19 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to ins pect the A T V bef ore oper ating. Failur e to pr operly m aintain t he A T V . WHA T CAN H APPEN Poor m aintenanc e increas es t he possibilit y of an acc ident or equipment dam age.
20 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to us e ext ra caut ion when operat ing t he A TV on unfam iliar terrai n. WHA T CAN H APPEN Unfamiliar t errain ma y cont ain hidden rocks, bumps, o r holes that could caus e loss of cont rol or overt urn.
21 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to us e ext ra caut ion when operat ing on exc essiv ely rough, s lippery or loose t err ain. WHA T CAN H APPEN Oper ating on ex cess ively r ough, s lippery or loose t err ain could cause los s of tr act ion or loss of c ontr ol, whic h could res ult in an accident or over tur n.
22 SA FETY Operator S afety POTENTI AL HAZ ARD T urning im proper ly . WHA T CAN H APPEN Im proper t urns could caus e loss of cont rol and lead t o a collis ion or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or tur ning as described in the owner ’s manual.
23 SA FETY Operator S afety POTENTI AL HAZ ARD Climbing hills im properly . WHA T CAN H APPEN Im proper hill c limbing could c ause loss of c ontr ol or over tur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or climbing hills as desc ribed in the owner ’ s manual.
24 SA FETY Operator S afety POTENTI AL HAZ ARD T rav eling downhill impr operly . WHA T CAN H APPEN Im proper ly descending a hill c ould cause los s of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or tr aveling down hills as descr ibed in the owner ’ s manual.
25 SA FETY Operator S afety POTENTI AL HAZ ARD Im properly cros sing hills and t urning on hills . WHA T CAN H APPEN Im proper ly cros sing or turning as hills could caus e loss of cont rol or overt urn.
26 SA FETY Operator S afety POTENTI AL HAZ ARD St alling, r olling backwar ds or impr operly dis mount ing while climbing a hill. WHA T CAN H APPEN The v ehicle could ov ert urn. HOW T O A VOID TH E HAZ ARD Maint ain st eady speed when climbing a hill.
27 SA FETY Operator S afety POTENTI AL HAZ ARD Im proper ly operat ing over obstac les. WHA T CAN H APPEN Oper ating ov er obst acles could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Bef ore operat ing in a new ar ea, chec k f or obst acles .
28 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CAN H APPEN T ires m ay float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an acc ident or overt urn. HOW T O A VOID TH E HAZ ARD Avoid operating t he A T V t hrough deep or f ast -f lowing wat er .
29 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV wit h improper t ires , or wit h improper or uneven t ire pr essur e. WHA T CAN H APPEN Use of impr oper tir es, or oper ation of the A T V wit h impr oper or uneven t ire pr essur e, could c ause loss of c ontr ol or acc ident.
30 SA FETY Operator S afety POTENTI AL HAZ ARD Ov erloading t he A TV or car rying/ t owing cargo im properly . WHA T CAN H APPEN Ov erloading and t owing can caus e changes in v ehicle handling, which could lead t o loss of c ontr ol or an acc ident.
31 SA FETY Operator S afety Af ter any over tur n or acc ident, have a qualif ied ser vice dealer inspect t he entir e vehicle f or pos sible damage, including ( but no t limited to) bra kes, t hro ttle and stee ring systems. Saf e operat ion of t his r ider- activ e vehicle r equires good judgement and physic al skills .
32 SA FETY Fuel Safety Gas oline is highly f lamm able and explosiv e under cer tain condit ions. S Always exerc ise ext rem e caut ion whenever handling gas o- line. S Always ref uel with t he engine st opped, and outdoor s or in a well vent ilated ar ea.
33 SA FETY Safety D ecals and Locations W arnin g decals h ave been placed on the A TV for your protecti on. R ead and f oll ow th e ins t ructi on s o f th e decals on th e A TV careful ly .
34 SA FETY Safety D ecals and Locations W ARNING 7077920 W ARNING Improper A TV use can r esu lt i n SEVER E INJUR Y or DEA TH ALW A YS USE AN APPRO VED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC .
35 SA FETY Safety D ecals and Locations Operat ing this A TV if you are under the age of 16 i ncreases your chan ce of severe i nj ury or d eat h. NEVER ope ra te t his ATV if y ou ar e under age 1 6. W ARNING 7078253 ALL WHE EL DRIVE SWITCH Do not push s witch to engage AW D if the rear wheels are spinning.
36 SA FETY Safe Riding G ear Always we ar c lothing suited to the t ype of riding. A TV riding requir es spec i al prote ctive clothing for c omfor t and to reduc e the cha nce of injury . 1. Helm et Y our he lmet is the most importa nt piece of prote ctive ge ar for sa fe riding.
37 FEATURE S AND CONTROLS Electr ical S witches Act ivat ing t he overr ide swit ch while t he thr ott le is open c an cause los s of cont rol, result ing in sev ere injury or deat h. Do not act ivat e the ov erride s witc h while the t hrot t le is open.
38 FEATURE S AND CONTROLS Light S witches The light sw itch is loca ted on the lef t hand leb ar (1). It’ s u sed t o tu rn the lights on and of f and to switch the lights fr om high bea m to low bea m. NOTE: The lights won’ t work unless the ke y is in the ON position and the shut-of f switc h i s in the RUN position.
39 FEATURE S AND CONTROLS Throttle Lever Engine spee d and vehic le moveme nt ar e contro lled by pr essing the throttle le ver . The throttle le ver (1) is spring loaded.
40 FEATURE S AND CONTROLS Br ake Lever The fro nt and rear brak es are app li ed by s queezi ng t he brak e leve r (1) towa rd the handle bar . The fro nt and rear brak es are hydra ulically a ctivate d disc type brak es th at are acti vat ed by o nl y one leve r .
41 FEATURE S AND CONTROLS Br akes Ch eck th e brake flu id l evel i n th e mas ter cyl in der b efore each u se o f the A TV . The ma ster cylinde r (1) is lo cated o n th e left h andl ebar . The f luid leve l ca n be se en thr ough an indica t or window (2) on the top of the maste r cylinder .
42 FEATURE S AND CONTROLS Park in g Brak e Setting the P arking Br ake 1. S queeze an d rel ease t he b rake l ever t wo o r thre e times, then squ eeze and ho ld . 2. Push the par k brake loc k (1) forw ar d to engage the bra ke. Rel eas e th e brake l ever .
43 FEATURE S AND CONTROLS Auxiliary Brake The a uxiliar y foot brake ( 1), i s loca ted on the inside of the right floorboa rd and is oper ate d by the right foot. The auxiliar y brake serv es as a backu p t o t he m ain bra ke system i f the main syste m bec omes inopera tive.
44 FEATURE S AND CONTROLS Choke The choke a ssists i n starting a c old engine. Ref er to the engine sta rting proc edur e on page 51 for corr ect choke and throttle se ttings during star ting. Fuel V alve The fu el v alv e (1) i s l ocat ed on th e left si de o f the vehic le, below the fe nder .
45 FEATURE S AND CONTROLS Autom atic T r ansm ission Gear Selector The tra nsmission gear se lector ( 1) is locate d on the right side of the vehic le. F: For wa rd N: Neutral R: Rev er se Whe never the A TV is left unattende d, alwa ys place the tra nsmission in gea r a nd lock the pa rking bra ke.
46 FEATURE S AND CONTROLS Recoil S tarter If the ba ttery has be en dra i ned o r dama ged a nd cannot star t the engine , use of the re coil star ter ( 1) will allow ve hicle ope ration until re pair s can be made . The rec oil star ter is locate d on the right side of th e mach in e.
47 FEATURE S AND CONTROLS All W heel Dr ive (A WD) S ystem Po lari s 4-wheel d rive A TVs are equippe d with a unique, Polaris exc lusive, A WD syste m that’ s ac tivated by a sw itch (1) on the right handle bar . When the switc h is off , the A TV is in 2 whee l drive at all times.
48 FEATURE S AND CONTROLS All W heel Dr ive (A WD) S ystem Di sengagi ng W heel H ubs Although the hubs norma lly disengage when ope ra ting in reve rse, one or both hubs may o ccasional ly rem ain engaged. If the h andlebars pul l to one side , it’ s likely tha t one fr ont hub is engage d .
49 OPERATION Br eak - In P er iod The br ea k-in per iod for your ne w 4-c ycle Polar is A TV is defined a s t he first ten hours of oper ation, or the time it ta kes to use the first two full tanks of ga soline. No single ac tion on your part is a s important a s following the proc edures for a prope r brea k-in.
50 OPERATION Pr e -Ride Inspection Use the f ollowing chec klist to verif y that your A TV is in proper wor king condition be fore each use. Item /Insp ectio n Procedu re 1. T ires - Che ck condition a nd pre ssure s. 2. Fuel and oil tanks - Fill both tanks to their prope r leve l s.
51 OPERATION Star ting the Engine S tar ting a Col d Engine 1. Place the tr ansmission in neutra l and loc k the par king bra ke. Make sur e the fue l t an k valve is on.
52 OPERATION Star ting the Engine S tar ting a Col d Engine 3. Move the engine stop switch to RUN . NOTE: Do not pre s s the throttle w hile starting the engine . 4. T urn the ignition ke y past the ON position to engage the sta rter . Activa t e the star ter for a maximum of five sec onds, re l ea sing the key when the engine sta rts.
53 OPERATION Star ting the Engine S tar ting a W ar m Engine W ar m engines do not normally requir e the use of the choke. Exce ssive use of the choke ca n cause the spa rk plug to become we t foule d. 1. Position the vehicle on a le vel surfa ce with the tra nsmission in neutr al.
54 OPERATION Hauling Cargo Acc essory r ac ks and hitc hes ar e a vailable fr om your Polar is dealer . Always re ad and unde rstand the load d istribution wa rnings on all warni ng l abel s, and n ever exceed t he sp ecifi ed weig ht cap ac ities for the vehic le.
55 OPERATION Hauling Cargo Pro cedu res and Precau tio ns S REDUC E S PEED AND ALLOW GREA TER DIS T ANCE FOR BR AKING WHEN HAULING CAR GO. S CARGO WEIGHT DI STR IBUTION should be 1/3 on the f ront rack and 2/3 on the re ar r ac k. When ope rating ove r rough or hilly ter rain, re duce spe ed a nd car go to maintain sta ble driving c onditions.
56 OPERATION Driving Safely Driving Pr o cedures 1. Sit upright with both feet on the footr ests a nd both hands on the handle bar s. 2. Start the e ngine a nd allow it to warm up, then shift the tra nsmission into gear . 3. Check your surr oundings and determine your path of tr ave l.
57 OPERATION Driving Safely Making T urns Y our Polar i s A TV is equippe d with a solid re ar a xle, whic h drive s both re ar wh ee ls equally at a ll times. This me ans that the whe el on the outside of the turn must travel a gre ate r distanc e than the inside wheel whe n turning and the inside tir e must slip trac tion slightly .
58 OPERATION Driving Safely Dr iving on Slippe r y Sur f aces Whenev er ridi ng o n sl ip pery su rfaces su ch as wet trai l s or lo ose grav el, or du ring freezi ng weat her , fol lo w thes e precaut io ns: 1. Slow down when e nter ing slippery a reas.
59 OPERATION Driving Safely Sidehilling Sidehilling ca n be a dange rous type of driving a nd should be avoided if at a ll possible. If you do e nter into a situa tion where sidehilling is neces sary , fol l ow t hes e precaut i ons : 1. Sl ow down. 2.
60 OPERATION Driving Safely Driving Uphill 25 _ Maximum W ARNING Brak ing and handling are gr eatly aff ect ed when operat ing in hilly ter rain. I mproper proc edure could c ause loss of c ontr ol or overt urn and r esult in ser ious injury or deat h.
61 OPERATION Driving Safely Driving Uphill Whe neve r trav eling uphill, follow these pr ecauti ons : 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ ma ximum). 3. Kee p both fe et on the f ootrests. 4. T ransfe r your weight forwa rd.
62 OPERATION Driving Safely Driving Downh ill Whe never de scending a hill, follow these pr ecauti on s: 1. P roceed di rect ly d own h ill. 2. T ransf er your we ight to the re ar of the ve hicle. 3. Sl ow down. 4. Apply the brakes slightly to aid in slowing, using the single br ake leve r .
63 OPERATION Driving Safely T urning A round on a H ill If the ve hicle stalls while c limbing a hill, never ba ck it down the hill! One mane uver that c an be used whe n it’ s nece ssar y to turn ar ound while c limbing a hill is the K-turn: 1. Stop and lock the pa rking bra ke while ke eping body we ight uphill.
64 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV c an ope rate through wa ter with a maximum re commende d depth e qual to the bottom of the footr ests (1) . F ollow th ese pro cedu res when oper ating through wa ter: 1. De termine wa ter depths a nd cur rent bef ore c rossing.
65 OPERATION Driving Safely Dr ivin g Over Obstacles Be al ert! L ook ah ead and l earn to read t he terrai n yo u’re trav eli ng on . Be con st ant l y alert fo r hazards s uch as l og s, ro cks an d lo w hangi ng bran ches . Sever e injury or death c an result if your v ehicle com es in cont act with a hidden obs tac le.
66 OPERATION Driving Safely Dr ivin g in Rever se F ol lo w th ese p recaut io ns when op erati ng i n revers e: 1. Always avoid ba cking downhill. 2. Bac k slowly . 3. When i n reverse, apply the brake s lightly for stopping. 4. A void turning at sharp angle s in reve rse .
67 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible . If it’ s unavoida ble, follow th ese p recaut io ns : 1. T urn the engine of f. 1. Place the tr ansmission in gear . 2. Set t he par king brake.
68 EMISSION C ON TR OL SYST EMS Noise E mi ssion Contr ol System Do not modify the engine, i ntake o r e xhaust components, as doing so may af fec t complianc e with state and loca l noise level requir ements.
69 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry powe r outlets provide 12V powe r for oper ating access ori es such a s hand held spot lights. Acce ssory outlets a re a vailable for all models. Contac t your P olar is dealer f or more informa tion.
70 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Hours of ope ration ar e based o n a 10 mph a vera ge. If ser vice is due a t 20 hours, the e quivale nt odomete r rea ding would be 200 mile s. P erform all s ervi ces at whi chever readi ng is reach ed first .
71 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks T a illigh t/b rak e ligh t Pre- Ride Pr e-Ri de Check operat ion dail y; ap- ply P olar is di ele.
72 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks Carbur etor f loat bowl 50 hr s. 6 mont hs Drai n bowl peri odicall y and pri or to stor age J Throt tl e Cable/ ETC Swit ch 50 hr s. 6 mont hs Inspect ; adjust ; lubr icat e; r eplace if necessar y L Choke (enr icher ) cable 50 hr s.
73 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks J L Fuel system 100 hr s. 12 months Check for l eaks at t ank cap, li nes, fuel val v e, f ilt er , pump and car buret or; r e- place l ines ever y two year s J Fuel fi lt er 100 hr s.
74 MAINTENANCE AND LUBRICATION Lubr ica tion R ecomm endations NOTE: Hour s are ba sed on 10 mph aver age. If se rvice is due a t 20 hours, the e quivale nt odomete r rea ding would be 200 mile s. P er form all serv ices at whi chev er readin g is reach ed firs t.
75 MAINTENANCE AND LUBRICATION Lubr ica tion R ecomm endations (3) (1) (4 ) (2) (5) (9) (8) (6) (10) (7) 4 or 8 o’cl ock posit ion- ( end view).
76 MAINTENANCE AND LUBRICATION Per iod ic Maintenan ce Recor d Use t he fol l owi ng ch art t o reco rd peri od ic m ain ten ance. Maintenance In terval Perfo rmed Se rv icing Date Ser vic ing Dealer or Pe rs on Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.
77 MAINTENANCE AND LUBRICATION Per iod ic Maintenan ce Recor d Use t he fol l owi ng ch art t o reco rd peri od ic m ain ten ance. Maintenance In terval Perfo rmed Se rv icing Date Ser vic ing Dealer .
78 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Pr emium 4 S ynth etic Oil Polaris Pre mium 4 All Sea son Synthetic e ngine oil has bee n specia lly for mulated for use in Polar i s 4-c ycle e ngines.
79 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations E ngine Oi l Chec k 1. Position the machine o n a level surf ace. 2. Start the e ngine a nd let it idle for 20-30 se conds, t hen stop the engine . 3. Remove the dipstic k (1), whi ch is l ocat ed on t he left side of the vehic le.
80 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Oil an d Filter Ch ange The r ec ommended oil ch ange inter val is 100 hours, 1000 miles, or every s ix m on th s, wh ich ever com es fi rst . Suggested br eak- in oil change is a t 20 hours, 200 miles, or one month, whiche ver c omes first.
81 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Oil an d Filter Ch ange 9. Place shop towe ls beneath the oil filte r (1) . Using a n oil filter wre nch, turn t he filte r counte rc lockwise to remove. 10. Usi ng a clean , d ry clot h, cl ean the filte r sea ling surfa ce on the crank case.
82 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations T ransm issio n Oil Check The tr ansmission lubrica nt level s hould be che cked e very six months or 1000 miles ( 1600 km), whic heve r come s first. Mainta in the oil leve l a t the bottom of the fill hole threa ds.
83 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Front Gearcase Oil Check The f ront gea rcase oil leve l s hould be che cked e very six months or 1000 miles ( 1600 km), whic heve r come s first. Mainta in the oil leve l a t the bottom of the fill plug threa ds.
84 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Drive Chain Polaris A TV drive cha ins are e quipped with o-r ing-sea led, perma nently greas ed pi ns and rol lers . Ho wever , th e out er su rfaces o f th e rol ler m us t be lubric ate d.
85 MAINTENANCE AND LUBRICATION Adju stment s T oe Alignm ent Use the following proce dure to chec k the t oe alignme nt of t he vehic le. The re comme nded toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set t he handle bars in a stra ight-a head position.
86 MAINTENANCE AND LUBRICATION Adju stment s Br akes The front and re ar brake s are hydra ulic disc brakes, activa ted by moving the single brake le ver towar d t he handle bar . These br ake s are self -a djusting. The fo ll owi ng checks are recom men ded t o k eep th e brak e sys tem i n good oper ating c ondition.
87 MAINTENANCE AND LUBRICATION Adju stment s Br akes 1. Ch eck t he b rake sy st em fo r fl ui d l eaks. 2. Ch eck t he b rakes for ex cess iv e trav el o r spongy fe el. 3. Ch eck th e fricti on p ads fo r wear , dama ge and looseness. 4. Ch eck th e securi ty an d su rface condition of the disc.
88 MAINTENANCE AND LUBRICATION Adju stment s Steer in g Assem b ly The ste er ing assembly of the A TV should be che cked pe riodically f or loose nuts and bolts. If loose nuts and bolts are f ound, see your Polaris dea ler for se rvice bef ore ope ra ting the vehicle.
89 MAINTENANCE AND LUBRICATION Adju stment s Handlebars The h and leb ars can b e adj us ted for rid er preference. 1. Remove the handle bar cove r to access t he hand leb ar bolt s (1). 2. Loosen the four bolts. 3. Adjust the handle bar to the desir ed height.
90 MAINTENANCE AND LUBRICATION Adju stment s Ca r bur etor IMPOR T ANT : Y our Polar i s A TV is c alibr ate d at the fa ctory for optimal pe rf orma nce at a ltitudes r anging f rom ze ro to 6,000 fee t (1800 m) and temper atures of +40 degr ee s F .
91 MAINTENANCE AND LUBRICATION Adju stment s Wheel Rem o val 1. Stop the engine , plac e the tra nsmission in gear a nd lock the par king bra ke. 2. Loosen the whe el nuts slightly . 3. Eleva te t he side of the veh icle by plac i ng a suitable sta nd under the foot rest fram e.
92 MAINTENANCE AND LUBRICATION Adju stment s Wheel Installation 1. Make sur e the t ra nsmission is in gea r with the par king brake lo cked . 2. P lace t he wh eel o n t he wh eel hub with the valve stem towar d the outside and the rota tion ar rows on the tire pointing to ward forward rot ati on.
93 MAINTENANCE AND LUBRICATION Adju stment s Fr ont Whee l Hub T ightening Front whee l bea ring tightne ss and spindle nut rete ntion are cr itical compone nt opera tions. All servic e must be pe rforme d by your aut ho rized P ol ari s deal er . Ti re T read Depth Alway s repl ace tires wh en tread depth is wor n t o 1/8 ″ ( .
94 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack Chec k the a mount of cha in slack in thr ee dif fe re nt locations by moving the ve hicle slightly f orwa rd to ga i n sla ck a t the top side of the r ear chai n. M easur e th e chai n sl ack at t he t ig ht est of t he t hree p os it io ns .
95 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack 6. R ol l t he A TV forward or b ackward to adjust the cha in slack to the prope r tension. See the illustra tion for pr oper splice link clip ope ning position (1) . 7. T ig ht en t he eccen tri c lo cki ng bo lt s to 30 ft.
96 MAINTENANCE AND LUBRICATION Engi ne Cooli ng System Coolant Level The re cover y bottle (1) is locate d on the left side of the machine . The fluid leve l must be maintained betw ee n the minimum and maximum mar ks on the bottle (whe n t he f l uid is cool) .
97 MAINTENANCE AND LUBRICATION Engi ne Cooli ng System Radiator Coolant L evel NOTE: This pr ocedure is re quire d only if the c ooling system has be en dr aine d for m ain ten ance and /o r repai r . Ho wever , if the re cove ry bottle has run dry , the leve l i n the radia t or should be inspecte d and co olan t add ed if neces sary .
98 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a halogen la mp, don’ t t ouch the lamp with ba re finger s. Oil from your skin le aves a re s idue , causing a hot spot tha t will shorten the life o f the lamp. Headlight L am p Replacement 1.
99 MAINTENANCE AND LUBRICATION Lights T aillight /Br akelig ht Lamp Replacement If the taillight/br akelight does not wo rk the lamp may ne ed to be repl aced. 1. Remove the ta illight lens cover mounting scre ws. Remove the lens c over a nd gasket and se t aside f or re asse mbly .
100 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service 1. Rem ov e th e seat , rel ease the clips, and remove the air box cover . 2. Loosen the cla mp and re m ove the filte r . 3. Remove the f abric type pre -filter ( 1) fr om the ma in filte r ( 2).
101 MAINTENANCE AND LUBRICATION Spar k P lugs Spar k plug condition is indic ative of e ngine ope ra tion. The spar k plug firing e nd condition should be re ad af ter the engine ha s bee n wa rmed up an d th e vehi cle has b een dri ven at h ig her sp eeds .
102 MAINTENANCE AND LUBRICATION V eh ic le Imme rsi o n If it’ s impossible to take your A TV to a deale r befor e starting it, follow the steps outlined below . 1. Move the A TV to dry land or at the ver y least, to wa ter be low the footr ests. 2.
103 MAINTENANCE AND LUBRICATION Recoil Hou sing T o preve nt possible engine dama ge, always dr ain the r ec oil housing (1) a f t e ro p e r a t i n gt h eA T Vi nv e r yw e t conditions.
104 MAINTENANCE AND LUBRICATION PV T System The basic ope ra tion of the P olar is P VT system is depende nt on engine sp eed and vehi cle t orq ue requ irem ent s. As engi ne s peed i ncreas es, t he for ce e xerte d on the m ovable d rive shea ve by the flyweights also incr ea ses.
105 MAINTENANCE AND LUBRICATION PV T System PVT Dryi ng There m ay be som e ins tan ces when wat er is acci dent ly i ng est ed in to the PVT system. Use the following instruc tions to dry it out befor e oper ating: 1. Remove the d ra in plug and allow the wa ter to dr ain.
106 MAINTENANCE AND LUBRICATION Spar k Ar r estor 1. Remove the ar restor cle an- out plug (1) fr om the bottom of the muf fle r . 2. Place the tr ansmission in neutra l and star t the engine. 3. Pur ge carbon fr om the system by momenta rily revving the e ngine seve ral time s.
107 MAINTENANCE AND LUBRICATION Batter y Batt ery Remov al 1. Disconne ct the hold-down str ap holding the batte ry in position, and re move batte ry cover . 2. Dis conn ect t he b lack (negat iv e) bat tery cabl e firs t. 3. Disc onnec t the red (positive ) batte ry ca ble last.
108 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age When th e vehi cl e is pl aced i n s to rage fo r th ree mo nt hs or m ore, t he batte ry should be re moved, stored out of the sun in a cool, dry pla ce and te sted monthly . Befor e r eusing, take the ba ttery to your de aler f or testing a nd rec har ging.
109 MAINTENANCE AND LUBRICATION Batter y Batt ery Cha rgin g NOTE: A lways ve rify batter y condition bef ore a nd 1-2 hours af ter the end of cha r ging. Stat e of Char ge Vo l t a g e Acti on Charge T ime* (Us ing cons tant cur rent char ger @ standard amps spec ified on top of battery ) 100% 12.
11 0 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 1 17 for the part number s of P olar is products. Cleaning th e A TV Kee ping your A TV cle an will not only improve its appe ara nce but it ca n also exte nd the life of va rious components.
111 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 1 17 for the part number s of P olar is products. Exterio r Make nec essar y re pair s and then c lean the A TV thoroughly with mild soap a nd warm w ater to re move all dirt a nd grime .
11 2 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 1 17 for the part number s of P olar is products. Flu id Levels Inspe ct the f ollowing fluid levels and c hange if nec.
11 3 MAINTENANCE AND LUBRICATION T r anspor ting the A TV Follow these proce dures when tra nsporting the vehic l e. 1. T urn off the e ngine and re move the key to prev ent loss during tra nsporting. 2. T urn the fuel valve of f. 3. Be s ure t he fu el cap , oi l cap and s eat are ins tal l ed correctl y .
11 4 SPECIFIC ATIO NS 2004 Scr am bler 500 4x4 Capac ities Body Styl e Gen III Gro ss V ehicle W eig h t 845 l bs . ( 383 kg) Fue l 3.5 ga l. ( 13.2 l ) Transm issio n Oi l 32 oz . ( 946 ml ) Coola nt 2.25 qt s. (2. 13 l) Engi ne Oi l 2 qt s . ( 1.89 l ) F ron t R ack (A ccessory ) 30 l bs.
11 5 SPECIFIC ATIO NS 2004 Scr am bler 500 4x4 Drive S ystem Dr ive Sys te m T ype PVT Shi ft T ype Side Le ver ( F-N- R) Ge ar Re duct ion - Reve rs e 4.
11 6 SPECIFIC ATIO NS 2004 Scr am bler 500 4x4 Jetting Chart Altitu d e AMBIENT TEMPERA TURE Below 40 ° F (B elow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (F eet) 0-1800 (0- 6000) 160 155 1800-3700 (6000- 12000) 152.
11 7 POLARIS PRODUCTS Part No. Descr ipt ion Engine Lubr icant 2870791 Fogging O il ( 12 oz. Aer osol) 2871281 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( qt. ) 2871844 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( gal.) 2871567 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( 16 gal.
11 8 TROUB LES HOOTIN G Contac t your P olar is dealer f or servic e if you’re una ble to identify solutions using the follow i ng ch ar ts. Dr ive Belt an d Cover Pr o blems Po ssib l e Cause Solution Dr ivi ng t he A TV ont o a p icku p o r tall trailer in hi gh ra nge .
11 9 TROUB LES HOOTIN G Engine Doesn’t T urn Over Po ssibl e Cause Sol uti on Trip ped circu it b reak er Reset th e b reak er Lo w b attery v o ltag e Re c ha r ge bat te ry t o 12.
120 TROUB LES HOOTIN G Engine Backfir es Po ssibl e Cause Sol uti on W ea k spa r k fr om s par k plugs In spect, clean an d/ or repl ace spark p lu g s In correct sp ark plu g g ap o r heat rang e Se.
121 TROUB LES HOOTIN G E ngine S tops or Loses P ower Po ssibl e Cause Sol uti on Out of fuel Tu rn fuel v alve to reserv e, refu el Ki nked or plugge d fue l vent l ine In spect an d rep lace W ater .
122 WARRANTY LIM IT ED W ARRANT Y Pol a ri s Sal es I nc ., 2100 Highwa y 55, Me dina , MN 55340, gi ves a SIX MONTH LI MI TED W ARRANTY on al l com pone nts of t he Pol a ri s Al l T e rr ai n V ehi cl e (A TV) aga ins t def ec ts i n ma te ri al or wor kma nshi p.
123 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TIO NS OF W ARRANTI ES AND REME DIE S ALL IM P LI ED W ARRANTIES ( INCLUDI NG BUT NOT LI MITED T O THE I MPLIED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD.
124 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE I F IT I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORIZED LOCA- TION.
125 INDEX A Accesso ries 6 9 ................... Adj ust ment s 85-95 ................ Ag e R estrictio ns 7 ................ Air F ilter 1 00 .................... Al l Whee l Dr ive 47- 48 ............. Au x iliary B rake 4 3 , 8 7 ............ A WD 47-48 .
126 INDEX O Oil 78 .......................... Oi l Change 80- 81 ................. Oil F ilter C han g e 8 0-8 1 ............ OPERA TIO N 49-67 ............... Ope ra tor Sa fe ty 7-31 ............... Ov errid e S witch 3 7 ............... P Park in g B rake 4 2 .
デバイスPolaris Scrambler 500 4x4の購入後に（又は購入する前であっても）重要なポイントは、説明書をよく読むことです。その単純な理由はいくつかあります：
Polaris Scrambler 500 4x4をまだ購入していないなら、この製品の基本情報を理解する良い機会です。まずは上にある説明書の最初のページをご覧ください。そこにはPolaris Scrambler 500 4x4の技術情報の概要が記載されているはずです。デバイスがあなたのニーズを満たすかどうかは、ここで確認しましょう。Polaris Scrambler 500 4x4の取扱説明書の次のページをよく読むことにより、製品の全機能やその取り扱いに関する情報を知ることができます。Polaris Scrambler 500 4x4で得られた情報は、きっとあなたの購入の決断を手助けしてくれることでしょう。
Polaris Scrambler 500 4x4を既にお持ちだが、まだ読んでいない場合は、上記の理由によりそれを行うべきです。そうすることにより機能を適切に使用しているか、又はPolaris Scrambler 500 4x4の不適切な取り扱いによりその寿命を短くする危険を犯していないかどうかを知ることができます。
ですが、ユーザガイドが果たす重要な役割の一つは、Polaris Scrambler 500 4x4に関する問題の解決を支援することです。そこにはほとんどの場合、トラブルシューティング、すなわちPolaris Scrambler 500 4x4デバイスで最もよく起こりうる故障・不良とそれらの対処法についてのアドバイスを見つけることができるはずです。たとえ問題を解決できなかった場合でも、説明書にはカスタマー・サービスセンター又は最寄りのサービスセンターへの問い合わせ先等、次の対処法についての指示があるはずです。
