Instruction/ maintenance manual of the product 500 2X4 International Polaris
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P antone 425 C W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without proper training or instruction. S at speeds too fast for your skills or the conditions. S on public roads - a collision can occur with another vehicle.
1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line of utility and recreati onal products.
2 POLARIS and POLARIS TH E W A Y OUT are regi stered tradem arks of Polaris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication.
3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 22 Operation . . . . . .
4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal inju ry hazard.
5 INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This vehicle is not a toy and can be hazardous to operate. A collision or ro llover can occur quickly , even during routine maneuvers, if you fail to take proper precautions.
6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er in the spaces provided. Remove the spare ke y and store it in a safe place.
7 SAFETY Safety T raining When you purchased your new Polaris vehicle, yo ur dealer offered a hands-on safety training course. Y ou were also provided with printed materials that explain safe operatin g procedures. Review this informa- tion on a regular basis.
8 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury . Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Ca nada bear a U.S. Dep artment of T ransportation (DOT) label.
9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE ) bearing markings such as VESC 8, V -8, Z87 .
10 SAFETY Operator Safety Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’ s manual.
11 SAFETY Operator Safety Handling Gasoline Gasoline is highl y flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling g asoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area.
12 SAFETY Operator Safety Never consume alcohol o r drugs before or while operating this vehicle. Keep both hands on the handl ebars. Keep both feet on the footrests. Never carry a passenger . Th e purpose of the long seat is to allow the operator to shift position as needed during operation.
13 SAFETY Operator Safety Never carry a passenger on the rear ra ck. Ejection from the vehicle or contact with moving components can result in serious injury or death. Operating on paved surfaces ma y serious ly affect the handling and control of the Quadricycle and could result in loss of control, acci dent and/or injur y .
14 SAFETY Operator Safety Always follow the procedures outli ned in this manual for turnin g. Never turn sharply at excessive speeds, which can lead to vehicle overturn. See page 37. Never attempt jumps or other stunts. Always follow the pro cedures outlined in this manual for drivin g through water .
15 SAFETY Operator Safety Always follow the pro cedures outlined in this manual for driving on hills. See page 39. Never operate on hills too steep for this vehicle or for your abilities. Practice on smal ler hills before attempting larger hills. Avoid climbing hills steeper than 25 ° .
16 SAFETY Operator Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Always travel slowly when operating on unfamiliar terrain. U se extra cautio n. Always follow the procedures outlined in this manual for driving in reverse.
17 SAFETY Operator Safety Never operate this vehicle on a frozen body of water . Never modify a Quadricycle through imprope r installation or use of accessories. Never exceed the stated load capacity fo r your vehicle. Cargo must be properl y distributed and securely attached.
18 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your p rotection. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual differ from the labels on your vehicle, always read and follow the instructio ns of the labels on the vehicle.
19 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper than 25 degrees 25 ° . T o pre- vent overturn on hilly terrain, use throttle and brakes gradually , and shift weight uphill. • REVERSE operation can be dangerous even at low speeds.
20 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a passenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 Tire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading can cause lo ss of control.
21 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under age 16. 7175374 Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch gu ard.
22 FEA TURES AND CONTROLS Switches Override Switch This vehicle is equipped with a re verse speed limiter sys tem. T o gain additional wheel speed while backing, release the throttle and press the override switch.
23 FEA TURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn th e li ghts on and o ff and to chang e the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights.
24 FEA TURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. Failure to check or maintain proper operation of the th rottle system can result in an accident if the thrott le lever sticks during opera tion.
25 FEA TURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydrau lically activ ated disc type brakes that are ac tivated by only one lever . Always test brake lever travel and master cylinder fluid level before riding.
26 FEA TURES AND CONTROLS Parking Brake 1. Place the transmission in gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lock, squeeze and release the brake lever .
27 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxiliary r ear brake when backing down a hill may cause rear tipover , which could result in serious injury or death. Never back down a hill. Use caution when ap plying the auxiliary brake.
28 FEA TURES AND CONTROLS Choke The choke assists in s tarting a cold engine. Refer to the engine starting procedure on page 34 for correct ch oke and throttle settings during start- ing. Fuel T ank Cap Always refuel with the engine stopped, and outdoors or in a well ventilated area.
29 FEA TURES AND CONTROLS T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. F: Forward Gear N: Neutral R: Reverse T o shift gears, brake to a complete stop. When the engine is id ling, move the lever to the desired gear .
30 OPERA T ION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Rea d and understand all safety warnings outlined in the safety section of this owner ’s manual.
31 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 28. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 56. Add oil as need ed to maintain the level in the proper range.
32 OPERA T ION Safe Operation Practices 1. Complete the recommen ded safety training be fore operating this vehicle. See page 7. 2. Do not allow anyone un der 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical disabi lities to oper- ate this ve hicle.
33 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
34 OPERA T ION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in neutral. 3. Lock the parking brake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged.
35 OPERA TION S t arting the Engine 9. T urn the ignition key past the ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the engin e starts. NOTICE: Operating the vehicle immediately after starting could cause engine damage.
36 OPERA T ION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright. Kee p your feet on th e footrests. Keep both hands on the handlebars. 3. Squeeze the brake lever . 4. Star t the engine and allow it to warm up. 5. Shift the transmission into gear .
37 OPERA TION T urning the V ehicle T o turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. The same leaning technique should be used for turn ing in reverse. Practice making turns at slow speeds before attempting to turn at faster speeds.
38 OPERA T ION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precau tions: 1. Do not operate on excessively ro ugh, slippery or loose terrain. 2. Slow down when entering slippery areas.
39 OPERA TION Driving Uphill Braking and handling are greatly affe cted when operating in hilly ter- rain. Improper pro cedure could cau se loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill. 2.
40 OPERA T ION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a sidehill is unavoidable , follow these precautions: 1.
41 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. A void hills with excessively slippery or loose surfaces. 3. Shift body weight uphill. 4. Drive straight downhill. 5. Slow down. Never go down a hill at high speed.
42 OPERA T ION T urning Ar ound on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake wh ile keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine.
43 OPERA TION Driving Through W ater Y our Polaris vehicle can operate through water with a maximum recom- mended depth eq ual to the bottom of the footrests. Follow these proce- dures when operating through water: 1. Determine water depths and current before entering water .
44 OPERA T ION Driving Over Obst acles Follow these precautions whe n operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Be alert. W atch the terrain. Use extra caution 3. Never operate over large obstacles. 4. A void hazards such as logs, rocks and low branches.
45 OPERA TION Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the bra kes lightly for stopping. 5. A void turning at sharp angles.
46 OPERA T ION Hauling Cargo Overloading the vehicl e or carrying or to wing cargo i mproperly can al ter vehicle handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these precaution s when hauling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO.
47 OPERA TION Hauling Cargo Load Distribution Accessory racks and hitches are available from your Polaris dealer . Read and understand the load distrib u- tion warnings l isted on the vehicle warning labels.
48 OPERA T ION Parking on an Incline A void parking on an incline. If it' s unavoidable, follow these precau- tions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Always block the rear wheels on the do wnhill side.
49 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with gover nmental noise level requi rements.
50 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main tenance chart .
51 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked wi th a could result in component failure and cause an accident, wh ich may result in se rious injury o r death. Always have an authorized Pola ris de aler perform these services.
52 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever main te nance interval is re ached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
53 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Engine oil change (break-in) 25 1 M 250 (400) P erform a break-in oil change X General lubrication 50 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.
54 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
55 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 50. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS P erformance Synthetic 2W-50 See page 56.
56 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil.
57 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 50. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine.
58 MAINTENANCE Oil and Filter Change 8. Place towels under the oil filter . Using an oil filter wrench, turn the filter counterclockwise to remove it. 9. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition.
59 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenev er the oil hose connection between the oil tank and pump inlet has been disconnected.
60 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 50. Maintain the oil level within the SAFE oper ating range on the dipstick. T ransmission Oil Recommendations Oil Check 1.
61 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan beneath the transmission oil drain plug area. 3. Loosen the jam nut. 4. T urn the adjuster bolt in to allow the removal of the drain plug. 5. Remove the dra in plug and w ipe the magnetic end clean to remove accumulated metallic filings.
62 MAINTENANCE Brakes Brake Fluid An over-full master cyl inder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Once open, a bottle of brake fl uid absorb s moistu re from the air , which causes the boiling temperature of the brake fluid to drop.
63 MAINTENANCE Brakes Brake Fluid (Hand Brake) Check the brake fluid level in the master cylinder be fore each use of the vehicl e. The master cyl inder is located on the left handlebar . Maintain the fluid level 1/4" (6 mm) below the top edge of the master cylinder .
64 MAINTENANCE Brakes Brake Check Perform the followin g checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily during normal opera- tion. 1. Always keep foot brake fluid at an adequate level. Check the foot brake system regularly for fluid leaks.
65 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent is 3-6 mm toe out. W ARNING! Severe injury or death can result from improper to e alignment and adjustment. Do not attempt to adju st tie ro d alignment.
66 MAINTENANCE S teering Assembly Check the steering assembly of the vehicle periodically for loose nu ts and bolts. If loose nuts and bolts are found, se e your Polaris dea ler for service before operating the vehicle.
67 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Slide the boots off the inline cable adjuster sleeve. Loosen the adjuster locknut. 2. T u rn the adjuster until 1.6-3 mm of freeplay exists at the lever . Move the throttle lever back and forth several times while adjusting.
68 MAINTENANCE Handlebars W ARNING! Improper adjustme nt of the handleba rs or incorrect torqui ng of the adjuster block tightening bolts can caus e limi ted steering or loosenin g of the handlebars, resulting in loss of co ntrol and serious injury or death.
69 MAINTENANCE Carburetor Y our Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C.
70 MAINTENANCE Drive Chain Drive Chain Lubrication The drive chai ns are equipped wit h o-ring-sealed, permanently greased pins and rollers. Howeve r , the outer surfaces of the roller must be lubri- cated. Always inspect the drive chain prior to operating the vehicle.
71 MAINTENANCE Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at th e tightest of the three positions.
72 MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or back- ward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position. 7. T ighten the eccentric locking bolts to 30 ft.
73 MAINTENANCE Cooling System The engine coolant level is controll ed, or main tained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
74 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair .
75 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and replace burn ed out lamps promptly . Always make sure lights are adjusted properly for best visibility .
76 MAINTENANCE Light s T aillight/Brakelight Lamp Replacement 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly . 2. Remove the lamp. 3. Apply dielectric grease to the socket and install the new lamp.
77 MAINTENANCE Ti r e s Operating your vehicle with worn tires, i mproperly infl ated tires, no n-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follow all tire maintenance procedures as outlined in this manual a nd on the labels on the vehicle.
78 MAINTENANCE Ti r e s Wheel Removal 1. Position the vehicle on a level su rface. Place the tr ansmission in gear . Lock the parking brake. 2. Loosen the wheel nuts slightly . 3. Safely place jackstands under the vehicle. 4. Remove the wheel nuts. Remove the wheel.
79 MAINTENANCE Ti r e s Wheel Nut T orque Specifications Check the wheel nut torques occasional ly and when they 've been loos- ened for service. Item T orque Specification F ront Wheel Nuts 27 ft. lbs. (37 Nm) Rear Wheel Nuts 50 ft. lbs. (68 Nm) Rear 50 ft.
80 MAINTENANCE Air Filter 1. Position the vehicle on a level su rface. Place the tr ansmission in gear . Lock the parking brake. 2. Remove the seat. 3. Release the air box cover clips, and remo ve the air box cover . 4. Loosen the clamp and remove the filter .
81 MAINTENANCE Breather Filter 1. Remove the clamps and pull the breather filter out of the hoses. It's not necessary to remove the lower hose from the engine. 2. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging.
82 MAINTENANCE Spar k P l ug s Sp ark Plug Recommendations Refer to the specifications sect ion beginning on page 1 02 for the recom- mended spark plug ty pe and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
83 MAINTENANCE Spar k P l ug s Sp ark Plug Condition Normal Spark Pl ug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service.
84 MAINTENANCE V ehicle Immersion If the vehicle stops while fully su bmerged, major engine damage can result if the machine is not thoroughl y inspected. T ake the vehicle to your dealer before starting the eng ine. If it's impossible to take your vehicle to a dealer before starting it, fol- low the steps outlined below .
85 MAINTENANCE S p ark A rrestor Failure to heed the following warnings whil e servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protec tion and leather work gloves.
86 MAINTENANCE P VT System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a hig h speed. The PVT system has been precision balanced.
87 MAINTENANCE P VT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt.
88 MAINTENANCE P VT System PVT Drying There may be some instances when wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Move the vehicle out of the water . 2. Remove the PVT drain plug.
89 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosio n and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , always connect the negative (black) cable last.
90 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parking brake. 3. Disconnect the battery hold-down strap. 4. Remove the battery cover . 5. On conventional batteries, re move the battery vent tube. 6. Disconnect the black (negative) battery cable first.
91 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructio ns on page 93 before installing the battery .
92 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three mo nths or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e and recharge as needed to mainta in a full charge.
93 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electroly te during charging. See page 90. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating.
94 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. State of Charge V oltage Action Charge Time (Using constant cu rrent charger @ standard amps specifie d on top of batt ery) 100% 12.
95 MAINTENANCE Cleaning and St orage W ashing th e V ehicle Keeping the vehicle clean will ex tend the life of components. NOTICE: High water pressure may damage comp onents. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.
96 MAINTENANCE Cleaning and St orage W ashing the V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution.
97 MAINTENANCE Cleaning and St orage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
98 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps NOTICE: S tarting the engine during the storage perio d will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended.
99 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Fluid Levels Inspect the fluid levels. Change fluids as recommende d in the Periodic Maintenance Chart beginn ing on page 50. • T ransmission • Brake fluid (change every two years and any time the fluid loo ks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1.
100 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Inspect and Lubricate Inspect all cables and lu bricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 50. Battery Storage See page 92-94 for storag e and char ging procedures.
101 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat.
102 SPECIFICA T IONS * Based on EU Directive 76/432/EC Scrambler 500 2X4 Maximum W eight Capacity 3 05 lbs. (138 kg) (includes weight of opera- tor , cargo and accessories) Dry W eight 530 lbs. (240 kg) Fuel Capacity 3.5 gal. (13.2 l) Engine Oil Capacity 2 qts.
103 SPECIFICA T IONS Jetting Chart Clutching Chart Scrambler 500 2X4 Driving System T ype PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (F/N/R) Gear Reduction, Reverse 3.05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 12/36 76P Drive Chain 520 O-Ring T ires/Pressure, Front 23 x 7-10 (4 psi/27.
104 POLARIS PRODUCTS P art # Description Engine Lubri cant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthet ic 2W-50 4-Cycle Oil (gal./3.8 l) Gearcase / T r ansmission Lubricants 2873602 Premium AGL Synthetic Gear case Lubricant (q t.
105 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Starting out going up a steep incl ine Use low range (if equipped) or turn around using the K- turn (see page 42). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or u se low range (if equipped) more frequently .
106 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breake r Reset the brea ker Low battery voltage Recharge the battery to 12.
107 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended fuel Incorrect ignition timi.
108 TROUBLESHOOTING Engine Stop s or Loses Power Possible Cause Solution Out of fuel T urn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel .
109 W ARRANTY LIMITED W ARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED W ARRANTY on all components of the Polaris Quadricycle ag ainst defects in material or workmanshi p. This warranty covers the parts and labor charges for repair or replacement of defective parts which are cove red by this warranty .
110 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIE S ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P A R- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE TWO YEAR W ARRANTY PERIOD.
111 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS.
112 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS.
11 3 INDEX A Air Filte r . . . . . . . . . . . . . . . . . . . . . . 80 B Battery . . . . . . . . . . . . . . . . . . . . 89-94 Charging (Conventional) . . . . . 93 Charging (Sealed) . . . . . . . . 93-94 Fluid (Conventional) . . . . . . . . . 92 Installation .
11 4 INDEX I Idle RPM Adjust ment . . . . . . . . . . . 69 Immersion . . . . . . . . . . . . . . . . . . . . 84 Indicator Lights . . . . . . . . . . . . . . . . 23 J Jetting Chart . . . . . . . . . . . . . . . . . . 103 K Key Switch. . . . . . . . . .
11 5 INDEX T Throttle Cable Freeplay . . . . . . . . . . 67 Throttle Leve r . . . . . . . . . . . . . . . . . . 24 Tires . . . . . . . . . . . . . . . . . . . . . . 77-79 Tread Depth . . . . . . . . . . . . . . . 77 Wheel and Hub Tightening . . . . 77 Wheel Installation .
An important point after buying a device Polaris 500 2X4 International (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris 500 2X4 International yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris 500 2X4 International - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 500 2X4 International you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 500 2X4 International will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 500 2X4 International, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris 500 2X4 International.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 500 2X4 International. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 500 2X4 International along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
