Market Segment:
High-performance All-Terrain Vehicle (ATV) for recreational and utility use.
Competitors:
Yamaha Wolverine, Honda FourTrax, Can-Am Outlander (in comparable engine displacement categories).
Key Features:
500cc engine, selectable 2WD/4WD, independent front suspension, MacPherson strut rear suspension, powerful braking system, robust chassis.
Manual Value Proposition:
Provides factory-level diagnostic and repair information, empowering owners and technicians to maintain and repair the Polaris Scrambler 500 accurately and efficiently.
Delivery:
Instant Download, No Shipping Cost.
Covered Areas:
Engine, Transmission, Drivetrain, Suspension, Brakes, Electrical System, Bodywork, Chassis, Fuel System, Cooling System, Lubrication System, Ignition System, Starting System, Exhaust System, Frame, Steering System, Wheels and Tires, Instrumentation, Accessories, Troubleshooting, Maintenance, Repair Procedures, Specifications.
Manual Type:
Complete Official Factory Service / Repair / Workshop Manual
Delivered Format:
PDF Download
Engine:
Complete engine disassembly, assembly, inspection, and repair. Covers cylinder head, camshaft, valve train, piston, rings, connecting rod, crankshaft, oil pump, lubrication system, timing, and ignition.
Transmission:
Service and repair of the automatic transmission, including fluid changes, torque converter, and internal components.
Drivetrain:
Covers front and rear drive shafts, differentials, axle shafts, CV joints, and U-joints.
Suspension:
Front and rear suspension components, including A-arms, shocks, springs, bushings, and wheel bearings.
Brakes:
Hydraulic brake system, including calipers, master cylinder, brake lines, brake pads, brake discs, and bleeding procedures.
Electrical System:
Wiring diagrams, troubleshooting electrical faults, battery, starter, alternator (if applicable), lighting, ignition system components, and sensors.
Fuel System:
Carburetor service and adjustment, fuel pump, fuel filter, fuel tank, and fuel lines.
Cooling System:
Radiator, cooling fan, thermostat, coolant hoses, and fluid specifications.
Lubrication System:
Engine oil, oil filter, oil passages, and lubrication procedures.
Bodywork Chassis:
Frame inspection, body panels, fenders, racks, seat, handlebars, and footrests.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, tire rotation, and general inspection.
Troubleshooting:
Diagnostic procedures for common problems, fault codes, and systematic troubleshooting guides.
Repair:
Step-by-step repair instructions for all major components and systems, including torque specifications and special tool requirements.
Rebuilds:
Detailed procedures for engine and transmission rebuilds.
Adjustments:
Carburetor adjustments, valve adjustments, clutch adjustments, and brake adjustments.
Disassembly Assembly:
Comprehensive instructions for disassembling and reassembling all major vehicle components.
Depth:
Full workshop level, covering everything from routine maintenance to complete engine and transmission rebuilds, including advanced diagnostics and specifications.
Engine Type:
4-stroke, SOHC, Single Cylinder
Bore X Stroke:
92mm x 75mm
Cooling System:
Liquid-cooled
Horsepower:
Approx. 30-32 HP (rated)
Torque:
Approx. 28-30 lb-ft (rated)
Fuel Delivery:
Carburetor (Mikuni BSR42)
Fuel Type:
Unleaded Gasoline (91 Octane Recommended)
Ignition System:
Electronic Ignition (CDI)
Oil Capacity:
Approx. 2.1 quarts (2.0 L)
Recommended Oil:
Polaris Premium 4 10W-40 Synthetic or API SG/SH/SJ certified SAE 10W-40 oil.
Transmission Type:
Automatic (Polaris Variable Transmission - PVT) with engine braking
Optional Transmission:
N/A
Drive Modes:
2WD/4WD (On-Demand)
Gear Selection:
High, Low, Neutral, Reverse, Park
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Oil or SAE 80W-90 GL-5 Gear Oil
Transmission Fluid Capacity:
Approx. 0.47 quarts (0.44 L)
Oil Change Interval:
Every 100 hours or 6 months, whichever comes first.
Air Filter Cleaning:
Clean every 25 hours or more frequently in dusty conditions.
Spark Plug Replacement:
Recommended every 100 hours or 12 months.
Transmission Fluid Change:
Every 100 hours or 12 months.
Coolant Type:
Polaris Premium 2-Stroke Premix (or equivalent ethylene glycol-based coolant with corrosion inhibitors).
Coolant Capacity:
Approx. 1.8 quarts (1.7 L)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Common Wear Items:
Tie rod ends, wheel bearings, brake pads, drive belt in PVT system, shock bushings.
Carburetor Tuning:
Carburetor can be sensitive to altitude and temperature changes, requiring periodic adjustment or cleaning.
Electrical Connections:
Corrosion in electrical connectors can lead to intermittent issues if not properly maintained.
Brand History:
Polaris Industries is a long-standing American manufacturer known for its snowmobiles, ATVs, and off-road vehicles.
Scrambler Lineage:
The Scrambler line has historically been Polaris's sport-oriented ATV offering, known for its performance and handling.
Manufacturing Location:
Primarily manufactured in Spirit Lake, Iowa, USA, and Mexico.
Production Years:
Polaris Scrambler 500 models have been produced for many years, with significant updates in different generations.
