2006 Polaris Scrambler 500 2x4 Owners Manual

2006 Polaris Scrambler 500 2x4 Manual

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2006 Polaris Scrambler 500 2x4 manual content summary:

  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 1
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    contains chemicals known to cause cancer, birth defects or other reproductive harm. 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 if it has been removed, please call 1-800-342-3764 for assistance.
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 4
    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 5
    or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2006 Scrambler 500 4X4 Owner's Manual P/N 9920153 2
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    TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS ...5 SAFETY ...6 FEATURES AND CONTROLS ...31 OPERATION ...43 EMISSION CONTROL SYSTEMS ...61 MAINTENANCE AND LUBRICATION ...62 SPECIFICATIONS ...104 POLARIS PRODUCTS ...107 TROUBLESHOOTING ...108 WARRANTY ...112 MAINTENANCE LOG ...116 INDEX ...118 3
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    4
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    VEHICLE IDENTIFICATION NUMBERS Record your ATV's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 9
    routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating a Polaris ATV. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16
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    symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The damage to the vehicle. NOTE: A note will alert you to important information or instructions. 7
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    Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV
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    . To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following
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    S Never exceed the stated load capacity for your ATV. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. S Always remove the ignition key when the vehicle is not in use
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    SAFETY WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident the skills learned in the course and the operating techniques described in the owner's manual. For more information about the training course, contact an authorized ATV dealer or
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 15
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry
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    Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states
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    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/
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    ATV before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual. 15
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    SAFETY Operator Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator's foot
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    loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. 17
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    could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner's manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively
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    of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 55. Always check the terrain carefully before descending a hill. Shift
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    Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 56. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always
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    uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. See page 56. 21
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    such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction
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    Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-
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    and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. See page 48. WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN
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    injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of
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    SAFETY Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near
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    of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement
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    SAFETY Safety Decals and Locations WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: 7172560 WARNING 7172566 7172667 28
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    This may cause severe drive shaft and clutch damage. See your Owner's Manual. 7079780 SAFETY Operating this ATV if you are under the age of Is Important. Adjust Freeplay to 3/16″ - 3/8″ DO NOT Overtension. See Owner's Manual. Torque Nut on Eccentric Bolts: To 30 Ft. Lbs. (For models without a
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    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.
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    Electrical Switches FEATURES AND CONTROLS 3 1 2 WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Override Switch (1) (Reverse Speed Limiter) This
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    FEATURES AND CONTROLS Light Switches WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It's designed for and must be used for off-road use only. Use caution and drive
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    or improperly operating throttle controls, which could cause an accident and lead to severe injury or death. Always contact your dealer for service repairs if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever
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    FEATURES AND CONTROLS Brake Lever WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. 1 The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar
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    Brakes FEATURES AND CONTROLS 1 2 Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the left handlebar. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This "eye" will appear dark when
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 39
    FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Squeeze and release the brake lever two
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    Auxiliary Brake FEATURES AND CONTROLS WARNING Aggressively applying the rear brake when backing downhill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear
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    . Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Refer to the specifications section at the rear of this manual for tank capacity. 1 Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hours of operation, or annually
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 42
    Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. F: Forward N: Neutral R: Reverse 1 F N R FEATURES AND CONTROLS CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage
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    FEATURES AND CONTROLS Recoil Starter If the battery has been drained or 2 1 damaged and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped
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    All Wheel Drive (AWD) System FEATURES AND CONTROLS Polaris 4-wheel drive ATVs are equipped with a unique, Polaris exclusive, AWD system that's activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV is in
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    for a short distance. Then proceed in forward again. NOTE: If the hubs remain engaged after following this procedure, return the ATV to your dealer for service. To continue using AWD in reverse, activate the override switch and the AWD switch. See page 31. WARNING Operating with only one front hub
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    Break-In Period OPERATION The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 47
    OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Pre-Ride Checklist Item Brake system / lever travel Brake fluid Auxiliary brake
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    Starting the Engine OPERATION WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. Starting a Cold Engine CAUTION Operating the vehicle immediately after starting could cause
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 49
    OPERATION Starting the Engine Starting a Cold Engine 4. Turn 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 engine starts. If the engine does not start, release the key and wait five seconds. Then activate
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    Driving Safely OPERATION Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking
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    labels, and never exceed the specified weight capacities for the vehicle. Maximum Towing Capacities Refer to the specifications at the rear of this manual for towing capacities. When towing, reduce the rear rack cargo load capacity by the amount of trailer tongue weight. Never tow any trailer
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    extra caution. Always attach the tow load to the hitch point designated for your vehicle. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. S EXTREME CAUTION MUST BE
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    must slip traction slightly. To make a 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. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 54
    Driving Safely OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 55
    overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling
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    injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. 53
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    OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain
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    the single brake lever. NOTE: Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill
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    OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8' (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine.
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    the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine. NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 61
    OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 62
    Driving Safely OPERATION Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. Driving in
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    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration. 4. Shut
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    Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Operation of
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    upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed
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    marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Perform all services at whichever maintenance interval is reached first. Item (whichever comes first) Hours Calendar Miles (Km) Pre-Ride Pre-Ride Pre-Ride
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    MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item (whichever comes first) Hours Calendar Miles (Km) 10 H 20 H 25 H 25 H 25 H 50 H 50 H 50 H 50 H 50 H 50 H 50 H 100 H 100 H 100 H 100 H 100 H Monthly Monthly Monthly Monthly Monthly 3M 6M 6M 6M 6M 6M 6M 6M 6M 12 M 12 M 12 M 100 (160) 200 (320
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    ) J Front wheel J Brake fluid Spark arrestor Idle speed J Toe adjustment Headlight aim " Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service J Have an authorized Polaris dealer perform these
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 69
    MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a-arms and lower control arms
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    Lubrication Recommendations MAINTENANCE AND LUBRICATION (2) (1) (3) (5) (4) (8) (6) (7) 4 or 8 o'clock position- (end view) 67
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    MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been
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    Engine Oil MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin. 1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the
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    MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change 9. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 10. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good
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    Engine Oil MAINTENANCE AND LUBRICATION Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line (1) approximately 2I from the oil tank (2), between
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    MAINTENANCE AND LUBRICATION Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level at the bottom of the fill hole threads. We recommend the use of Premium AGL Synthetic Gearcase Lubricant.
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    Front Gearcase Oil Oil Check MAINTENANCE AND LUBRICATION Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level at the bottom of the fill plug threads. We recommend the use of Polaris ATV Angle Drive
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    MAINTENANCE AND LUBRICATION Drive Chain Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or
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    front rim (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. 75
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    MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. The following checks are recommended to keep the brake system in good operating condition. Check more often if
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    Brakes MAINTENANCE AND LUBRICATION 1. Check the brake system for fluid leaks. 2. Check the brakes for excessive travel or spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64″
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    assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by
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    in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1 The handlebars can be adjusted for rider preference. 1. Remove the handlebar cover to access the handlebar bolts (1). 2. Loosen the four bolts
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    MAINTENANCE AND LUBRICATION Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes
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    an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in your owner's manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth
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    affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 2. Place the wheel on the wheel hub with the valve stem toward the
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    Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always pressure as outlined in this owner's manual. When replacing a tire always use original equipment size and type. 83
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    ) deflection. Use the following procedure if adjustment is required. 1 3/16″-3/8″ (.48 cm - .95 cm) 1. Remove the chain guard. 2. Loosen the chain guide. 3. Loosen the two eccentric locking bolts (1). 4. Loosen the caliper mounting 1 bolt located on the left side of the swing arm. 5. Insert a pin
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    places around the chain. NOTE: The chain is adjusted correctly when the tightest portion of the chain has approximately 3/8" (10mm) deflection. 11. Position the chain guide to allow 1/8" (3mm) clearance and tighten the retaining bolt to 5 ft. lbs. (7 Nm). 12. Reinstall the chain guard. 85
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    MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. The fluid level must be maintained between the minimum and maximum marks on the bottle (when the fluid is cool). 1 The engine coolant level is controlled or maintained
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    Engine Cooling System MAINTENANCE AND LUBRICATION WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level NOTE: This procedure is required only if the
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    dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently. Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight
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    Lights MAINTENANCE AND LUBRICATION Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1). 3. Apply
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    . Breather Filter/Hose CAUTION Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service. 1. Remove the clamps and pull the filter (1) out of the hoses. NOTE: It's not necessary to remove the lower hose from the
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 94
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 95
    . 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. NOTE: If water has been ingested into the PVT, follow the procedure on
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 96
    conditions. This should also be done before storing the ATV. Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. The drain screw is located at the bottom of the recoil housing. Use a wrench to remove the screw. Be sure to reinstall
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 97
    MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of "pinch"
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 98
    procedures. See your dealer as outlined in the owner's manual. This PVT system is intended for use on Polaris products water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug service as soon as possible. 95
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 99
    MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 100
    not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 98 before installing the battery. 1. Ensure that the battery is fully charged. 2. Set the battery in the battery holder. 3. Connect and
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 101
    and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 102
    Battery NOTE: MAINTENANCE AND LUBRICATION Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) State of Charge 100% 12.8-13.0 volts None, check at
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 103
    MAINTENANCE AND LUBRICATION Cleaning and Storage See page 107 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 104
    and promotes better starting after the storage period. 1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer. Follow the instructions on the container for the recommended amounts. 2. Start the engine and allow it to run for 15-20 minutes so the stabilizer can disperse
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 105
    every two years or as required if fluid looks dark or contaminated). Engine 1. Support the front end of the machine so the engine is level or tilted slightly lubrication guidelines in the maintenance section of the service or owner's manual to completely grease and lubricate the entire vehicle
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 106
    Transporting the ATV MAINTENANCE AND LUBRICATION Follow these procedures when transporting the vehicle. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly. 4. Always tie the
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 107
    SPECIFICATIONS 2006 Scrambler 500 4X4 Body Style Gross Vehicle Weight Fuel Transmission Oil Coolant Engine Oil Front Rack (Accessory) Rear Rack (Accessory) Hitch Towing Rating Hitch Tongue Weight Capacity Unbraked Trailer Towing Capacity* Turn Radius Ground Clearance Height Length Width Seat Height
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 108
    2006 Scrambler 500 4X4 Drive System Type Shift Type Gear Reduction - Reverse Gear Reduction - Forward Front Drive (ratio) Final Drive (ratio) Drive Chain Front Tires Rear Tires SPECIFICATIONS Drive System PVT Side Lever (F-N-R) 4.74/1 3.06/1 2/1 13/36 76P 520 O-Ring 23 x 7-10 (4 psi) 22 x 11-10 (3
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 109
    SPECIFICATIONS Jetting Chart Altitude Meters (Feet) AMBIENT TEMPERATURE 0-1800 (0-6000) 1800-3700 (6000-12000) 2006 Scrambler 500 4X4 Below 40° F (Below 5° C) 160 152.5 +40°F and above (+5°C and above) 155 147.5 Clutching Chart Altitude Meters (Feet) 0-1800 (0-6000) 1800 & above (6000 & above)
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 110
    POLARIS PRODUCTS Part No. 2870791 2871281 2871844 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2872073 2872348 2871323 2871534 2872889 2871326 2870652 2870990 2872893 2871956 Description Engine Lubricant Fogging Oil (12 oz. Aerosol)
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 111
    TROUBLESHOOTING Contact your Polaris dealer for service if you're unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or low ground speed (
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 112
    Engine Doesn't Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections TROUBLESHOOTING Solution Reset the breaker Recharge battery to 12.8 VDC Check all connections and tighten Check all connections and tighten Engine Turns Over,
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 113
    TROUBLESHOOTING Engine Backfires Possible Cause Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 114
    battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine TROUBLESHOOTING Solution Turn fuel valve to reserve, refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 115
    preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 116
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 117
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 118
    WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 119
    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 116
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 120
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 117
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 121
    INDEX A Age Restrictions ...6 Air Filter ...90 All Wheel Drive ...41-42 Auxiliary Brake ...37, 77 AWD ...41-42 E Engaging Wheel Hubs ...41 Engine Break-in ...43 Engine Cooling System ...86-87 Engine Storage ...102 Equipment Modifications ...10 Exhaust Emission Control System . 61 B Battery ...97-
  • 2006 Polaris Scrambler 500 2x4 | Owners Manual - Page 122
    33 Tire Tread Depth ...83 Toe Alignment ...75 Towing Capacities ...48 Transmission Gear Selector ...39 Transmission Oil ...72 Transporting the ATV ...103 TROUBLESHOOTING ...108-111 Turning Around on a Hill ...56 R Radiator Coolant Level ...87 Rear Drive Chain Slack ...84-85 Rear Spring ...78 Recoil
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