Polaris 4X4 Manuel d'utilisateur

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

97MAINTENANCE AND LUBRICATIONEngine Cooling SystemRadiator Coolant LevelNOTE: This procedure is required onlyif the cooling system has been drainedfor

98MAINTENANCE AND LUBRICATIONLightsWhen servicing a halogen lamp, don’t touch the lamp with barefingers. Oil from your skin leaves a residue, causing

99MAINTENANCE AND LUBRICATIONLightsTaillig ht/Brakelight Lamp ReplacementIf the taillight/brakelight does not work the lamp m ay need to bereplaced.1.

100MAINTENANCE AND LUBRICATIONFilter SystemsAir Filter Service1. Remove the seat, releasethe clips, and remove theair box cover.2. Loosen the clamp an

101MAINTENANCE AND LUBRICATIONSpark PlugsSpark plug condition i s indicative of engine operation. The spark plugfiring end condition should be read af

102MAINTENANCE AND LUBRICATIONVehicle ImmersionIf it’s impossible to take your ATV to a dealer before starting it, followthe steps outlined below.1. M

103MAINTENANCE AND LUBRICATIONRecoil HousingTo prevent possible engine damage,always drain the recoil housing (1)afteroperatingtheATVinverywetconditio

104MAINTENANCE AND LUBRICATIONPVT SystemThe basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As

105MAINTENANCE AND LUBRICATIONPVT SystemPVT DryingThere may be some instances when water is accidently ingested intothe PVT system. Use the following

106MAINTENANCE AND LUBRICATIONSpark Arrestor1. Remove the arrestor clean-outplug (1) from the bottom of themuffler.2. Place the transmission in neutra

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

107MAINTENANCE AND LUBRICATIONBatteryBattery Removal1. Disconnect the hold-down strap holding the battery in position, andremove battery cover.2. Disc

108MAINTENANCE AND LUBRICATIONBatteryBattery StorageWhen the vehicle is placed in storage for three months or more, thebattery should be removed, stor

109MAINTENANCE AND LUBRICATIONBatteryBattery ChargingNOTE: Always verify battery condition before and 1-2 hours after theend of charging.State ofCharg

110MAINTENANCE AND LUBRICATIONCleaning and StorageSee page 117 for the part numbers of Polaris products.Cleaning the AT VKeeping your ATV clean will n

111MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsSee page 117 for the part numbers of Polaris products.ExteriorMake necessary repairs and

112MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsSee page 117 for the part numbers of Polaris products.Fluid LevelsInspect the following

113MAINTENANCE AND LUBRICATIONTransporting the ATVFollow these procedures whentransporting the vehicle.1. Turn off the engine andremove the key to pre

114SPECIFICATIONS2004 Scrambler 500 4x4CapacitiesBody Style Gen IIIGross Vehicle Weight 845 lbs. (383 kg)Fuel 3.5 gal. (13.2 l)Transmission Oil 32 oz.

115SPECIFICATIONS2004 Scrambler 500 4x4Drive SystemDrive System Type PVTShift Type Side Lever (F-N-R)Gear Reduction - Reverse 4.74/1Gear Reduction - F

116SPECIFICATIONS2004 Scrambler 500 4x4Jetting ChartAltitude AMBIENTTEMPERATUREBelow 40° F(Below 5° C)+40°F and above(+5°C and above)Meters(Feet)0-180

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

117POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.

118TROUBLESHOOTINGContact your P olaris dealer for service if you’re unable to identifysolutions using the following charts.Drive Belt and Cover Probl

119TROUBLESHOOTINGEngine Doesn’t Turn OverPossible Cause SolutionTripped circuit breaker Reset the breakerLow battery voltage Recharge battery to 12.8

120TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

121TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line Ins

122WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITEDWARRANTY on all components of the Polaris A

123WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIEDWARR

124WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

125INDEXAAccessories 69...Adjustments 85-95...Age Restrictions 7...Air Filter 100...All Whe

126INDEXOOil 78...Oil Change 80-81...Oil Filter Change 80-81...OPERATION 49-67...Operator Sa

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

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

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

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

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

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

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

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

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

29SAFETYOperator SafetyPOTENTIAL HAZARDOperating this ATV with improper tires, or with improper oruneven tire 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 (butno

32SAFETYFuel SafetyGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gaso-line.S

33SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Readand follow the instructions of the decals on th

34SAFETYSafety Decals and LocationsWARNING7077920WARNINGImproper ATV u se can result in SEVERE INJURY or DEAT HALWAYS USEAN APPROVEDHELMET ANDPROTECTI

35SAFETYSafety Decals and LocationsOperating this ATV if you are underthe age of 16 increases your chanceof severe injury or death.NEVER operate this

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

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

37FEATURES AND CONTRO LSElectrical SwitchesActivating the override switch while the throttle is open cancause loss of control, resulting in severe inj

38FEATURES AND CONTRO LSLight SwitchesThe light switch is l ocated on the lefthandlebar (1). It’s used to turn thelights on and off and to switch thel

39FEATURES AND CONTRO LSThrottle LeverEngine speed and vehicle movementare controlled by pressing thethrottle lever. The throttle lever (1)is spring l

40FEATURES AND CONTRO LSBrake LeverThe front and rear brakes areapplied by squeezing the brakelever (1) toward the handlebar.The front and rear brakes

41FEATURES AND CONTRO LSBrakesCheck the brake fluid level in themaster cylinder before each use ofthe ATV. The master cylinder (1) islocated on the le

42FEATURES AND CONTRO LSParking BrakeSetting the Parking Brake1. Squeeze and release the brake lever two orthree times, then squeeze and hold.2. Push

43FEATURES AND CONTRO LSAuxiliary BrakeThe auxiliary foot brake (1), islocated on the inside of the rightfloorboard and is operated by theright foot.

44FEATURES AND CONTRO LSChokeThe choke assists in starting a cold engine. Refer to the engine startingprocedure on page 51 for correct choke and throt

45FEATURES AND CONTRO LSAutomatic Transmission Gear SelectorThe transmission gear selector (1)is located on the right side of thevehicle.F: ForwardN:

46FEATURES AND CONTRO LSRecoil StarterIf the battery has been drained ordamaged and cannot start theengine, use of the recoil starter (1)will allow ve

2Copyright 2003 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

47FEATURES AND CONTRO LSAll Wheel Drive (AWD) SystemPolaris 4-wheel drive ATVs areequipped with a unique, Polarisexclusive, AWD system that’sactivated

48FEATURES AND CONTRO LSAll Wheel Drive (AWD) SystemDisengaging Wheel HubsAlthough the hubs normally disengage when operating in reverse, oneor both h

49OPERATIONBreak-In PeriodThe break-in period for your new 4-cycle Polaris ATV is defined as thefirst ten hours of operation, or the time it takes to

50OPERATIONPre-Ride InspectionUse the following checklist to verify that your ATV is in properworking condition before each use.Item/Inspection Proced

51OPERATIONStarting the EngineStarting a Cold Engine1. Place the transmission in neutraland lock the parking brake.Make sure the fuel tank valve ison.

52OPERATIONStarting the EngineStarting a Cold Engine3. Move the engine stop switch t o RUN. NOTE: Do not press thethrottle while starting the engine.4

53OPERATIONStarting the EngineStarting a Warm EngineWarm engines do not normally require the use of the choke. Excessiveuse of the choke can cause the

54OPERATIONHauling CargoAccessory racks and hitches are available from your Polaris dealer.Always read and understand the load distribution warnings o

55OPERATIONHauling CargoProcedures and PrecautionsS REDUCE SPEED AND ALLOW GREATER DISTANCE FORBRAKING WHEN HAULING CARGO.S CARGO WEIGHT DISTRIBUTION

56OPERATIONDriving SafelyDriving Procedu res1. Sit upright with both feet on the footrests and both hands on thehandlebars.2. Start the engine and all

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

57OPERATIONDriving SafelyMaking Tu rnsYour Polaris ATV is equipped with a solid rear axle, which drives bothrear wheels equally at all times. This mea

58OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel,or during freezing weathe

59OPERATIONDriving SafelySidehillingSidehilling can be a dangerous type of driving and should be avoided ifat all possible. If you do enter into a sit

60OPERATIONDriving SafelyDriving Uphill25_MaximumWARNINGBraking and handling are greatly affected when operating in hillyterrain. Improper procedure c

61OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25_

62OPERATIONDriving SafelyDriving DownhillWhenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to

63OPERATIONDriving SafelyTurning Around on a HillIf the vehicle stalls while climbing a hill, never back it down the hill!One maneuver that can be use

64OPERATIONDriving SafelyDriving Through WaterYour ATV can operate through waterwith a maximum recommendeddepth equal to the bottom ofthe footrests (1

65OPERATIONDriving SafelyDriving Over ObstaclesBe alert! Look ahead and learn to read the terrain you’re traveling on.Be constantly alert for hazards

66OPERATIONDriving SafelyDriving in ReverseFollow these precautionswhen operating in reverse:1. Always avoid backingdownhill.2. Back slowly.3. When in

4

67OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline if possible. If it’s unavoidable, followthese precautions:1. Turn the engine of

68EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, i ntake or exhaust components, as doing somay affect compliance with

69MAINTENANCE AND LUBRICATIONAccessoriesAuxiliary power outlets provide 12V power for operating accessoriessuch as hand held spot lights. Accessory ou

70MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleHours of operation are based on a 10 mph average. If service is due at20 hours, the equivale

71MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours/MilesFrequency RemarksTaillight/brakelight Pre-Ride Pre-Ride Check operation dail

72MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours/MilesFrequency RemarksCarburetor floatbowl50 hrs. 6 months Drain bowl periodicall

73MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours/MilesFrequency RemarksJLFuel system 100 hrs. 12 months Check for leaks at tankcap

74MAINTENANCE AND LUBRICATIONLubrication RecommendationsNOTE: Hours are based on 10 mph average. If service is due at 20hours, the equivalent odometer

75MAINTENANCE AND LUBRICATIONLubrication Recommendations(3)(1)(4)(2)(5)(9)(8)(6)(10)(7)4 or 8 o’clockposition- (end view)

76MAINTENANCE AND LUBRICATIONPeriodic Maintenan ce RecordUse the following chart to record periodic maintenance.MaintenanceIntervalPerformedServicingD

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

77MAINTENANCE AND LUBRICATIONPeriodic Maintenan ce RecordUse the following chart to record periodic maintenance.MaintenanceIntervalPerformedServicingD

78MAINTENANCE AND LUBRICATIONLubrication RecommendationsPremium 4 Synthe tic OilPolaris Premium 4 All Season Synthetic engine oil has been speciallyfo

79MAINTENANCE AND LUBRICATIONLubrication RecommendationsEngine Oil Check1. Position the machine on a level surface.2. Start the engine and l et it idl

80MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil and Filter ChangeThe recommended oil change interval is 100 hours, 1000 miles, orevery six

81MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil and Filter Change9. Place shop towels beneath theoil filter (1). Using an oil filterwrench

82MAINTENANCE AND LUBRICATIONLubrication RecommendationsTransmission Oil CheckThe transmission lubricant level should be checked every six months or10

83MAINTENANCE AND LUBRICATIONLubrication RecommendationsFront Gearcase Oil CheckThe front gearcase oil level should be checked every six months or1000

84MAINTENANCE AND LUBRICATIONLubrication RecommendationsDrive ChainPolaris ATV drive chains are equipped with o-ring-sealed, permanentlygreased pins a

85MAINTENANCE AND LUBRICATIONAdjustmentsToe AlignmentUse the following procedure to check the toe alignment of the vehicle.The recommended toe alignme

86MAINTENANCE AND LUBRICATIONAdjustmentsBrakesThe front and rear brakes are hydraulic disc brakes, activated bymoving the single brake lever toward th

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

87MAINTENANCE AND LUBRICATIONAdjustmentsBrakes1. Check the brake system for fluid leaks.2. Check the brakes for excessive travel orspongy feel.3. Chec

88MAINTENANCE AND LUBRICATIONAdjustmentsSteering AssemblyThe steering assembly of the ATV should be checked periodically forloose nuts and bolts. If l

89MAINTENANCE AND LUBRICATIONAdjustmentsHandlebarsThe handlebars can be adjusted forrider preference.1. Remove the handlebar cover toaccess the handle

90MAINTENANCE AND LUBRICATIONAdjustmentsCarburetorIMPORTANT: Your Polaris ATV is calibrated at t he factory foroptimal performance at altitudes rangin

91MAINTENANCE AND LUBRICATIONAdjustmentsWheel Removal1. Stop the engine, place the transmission in gear and lock theparking brake.2. Loosen the wheel

92MAINTENANCE AND LUBRICATIONAdjustmentsWheel Installation1. Make sure the transmission is ingear with the parking brakelocked.2. Place the wheel on t

93MAINTENANCE AND LUBRICATIONAdjustmentsFront Wheel Hub TighteningFront wheel bearing tightness and spindle nut retention are criticalcomponent operat

94MAINTENANCE AND LUBRICATIONAdjustmentsRear Drive Chain SlackCheck the amount of chain slack in three different locations by movingthe vehicle slight

95MAINTENANCE AND LUBRICATIONAdjustmentsRear Drive Chain Slack6. Roll the ATV forward or backwardto adjust the chain slack to theproper tension. See t

96MAINTENANCE AND LUBRICATIONEngine Cooling SystemCoolant LevelThe recovery bottle (1) is locatedon the left side of the machine.The fluid level must