Polaris 2003 ATV Scrambler 500 4x4 - Manual

1
OWNER’S MANUAL SUPPLEMENT
2003 SCRAMBLER 500 4x4
IMPORTANT: This supplement to your owner’s manual should remain with your owner’s manual at all times.
Capacities
Body Style Gen III
Gross Vehicle Weight 845
Fuel Capacity 3.5 U.S. Gallons
Gearcase Oil 32 Ounces
Engine Oil Capacity 2 Quarts
Front Rack (Maximum Capacity) Accessory (30 lbs.)
Rear Rack Accessory (60 lbs.)
Tow Hitch Accessory
Hitch Tongue Weight Capacity 30 lbs.
Hitch Towing Rating 850 lbs. (386 kg)
Unbraked Trailer Towing Capacity* 1210 lbs. (549 kg)
Turn Radius 60 inches
Ground Clearance 5.5 inches
Height 47 inches
Length 74.5 inches
Seat Height 34 inches
Dry Weight 571 lbs.
Wheel Base 48.5 inches
Width 45.5 inches
Drive System
Drive System Type PVT
Shift Type Side Lever (F-N-R)
Gear Reduction - Low Not Applicable
Gear Reduction - Reverse 4.74 / 1
Gear Reduction - Foward 3.06 / 1
Front Drive (ratio) 2:1
Final Drive (ratio) 13/36 76P
Center Drive (ratio) Not Applicable
Drive Chain 520 O-ring
Front Tire 23 x 7 - 10
Rear Tire 22 x 11 - 10
Tire Pressure (front) 4 PSI
Tire Pressure (rear) 3 PSI
Suspension and Brakes
Front Susp. - Mac Strut 8.2 inches
Rear Susp. - Progresseive Rate
Swing Arm
10.5 inches
Shock Adjustment Thread Adjust
Front Brake Fixed disc, hydraulic floating
caliper
Rear Brake Hydraulic, opposed piston
caliper, rear axle fixed disc
Suspension and Brakes
Auxiliary Brake Hydraulic, opposed piston cali-
per, rear axle, fixed disc
Park Brake Hydraulic lock all wheel
Engine & Cooling
Engine Model Number EH50PLE-12
Engine Type 4 cycle, single cylinder
Lubrication Dry Sump
Bore x Stroke 92 x 75
Displacement 499
Compression Ratio 10:2
Engine Cooling Liquid
Alternator Output (watts) 250
Carburetion BST 40
Main Jet 155
Pilot Jet 40
Needle Jet Y-0
Pilot Screw 2.0
Jet Needle 6H25-94-3
Ignition CDI
Timing 30° @ 5000 ± 2
Spark Plug Gap .036 inches / .9 mm.
Spark Plug Type NGK BKR6E
Exhaust USFS Approved
Features
Headlight (watts) 2 dual beam, 30 / 30
Taillight (watts) 8.26
Brake Light (watts) 26.9
Battery 12 V 14 AH
DC Plug In - Rear Accessory
DC Socket - Forward Accessory
Electric Start Standard
High Beam Indicator Standard
High Temp Indicator Standard
Windshield Accessory
Low Oil Light Not Available
Neutral Indicator Standard
Reverse Indicator Standard
Speedometer Accessory
Tool Kit Standard
* Based on EU Directive 76/432/EC
Carburetor Jetting Clutching Chart
Alti-
tude
AMBIENT
TEMPERATURE
Below +40° F
Below +5° C
+40° F &
Above
+5° C &
Above
Altitude Shift
Weight
Drive-
Clutch
Spring
Driven-
Clutch
Spring
Helix
Spring
Me-
ters
(Feet)
0-1800
(0-6000)
160 155 Me-
ters
(Feet)
0-1800
(0-6000)
10WH
(5630710
)
Blue/
Green
( 7041157)
Silver
(7041499)
40°
(5131446)
1 + 1
1800 & above
(6000 & above)
152.5 147.5 1800 & above
(6000 & above)
10RH
(5630709)
Blue/
Green
(7041157)
Silver
( 7041499)
40°
(5131446)
1 + 1
PN 9917510 Rev 01 2/02
E
2002 Polaris Sales Inc.
Printed in U.S.A.