Polaris Hawkeye 300 4X4 manuel d'utilisation

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A card contain ing importan t A TV safety informa tion should be attached to the owner's man ual on the next pag e. If you cannot locate th is card, or if it has been removed, plea se call 1-8 00-342- 3764 for assistance. W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductiv[...]

1 WELCOME Thank you for purch asing a Polaris vehicle, an d welcome to our world- wide family of Polaris owners. W e proudly pro duce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excellence for a ll[...]

2 POLARIS and POLARIS THE W A Y OUT are regist ered trademarks of Polaris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of pub lication. Due to constant improvements in the design and quality of production compo nents, some minor discrep[...]

3 T ABLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F eatures and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Emission Control Systems . . . . . . . . . . . . . [...]

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5 KNOW Y O UR VEHICLE As the operator of the vehicle, yo u are responsible for your persona l safety , the safety of others, and the protection of our environment. Read and understand your o wner's manual, which includes valuable informa- tion abou t all aspects of your vehicle, including safe operating proce- dures. V ehicle Identification Nu[...]

6 SAFETY Safety Decals and Locations W arning decals have been placed o n the A TV fo r your protection. Read and follow the instructions of the de cals on the A TV carefully . If any of the decals depicted in this manu al dif fer from the decals on your A TV , always read and follow the instruc tions of the decals on the A TV . If any decal become[...]

7 SAFETY Safety Decals and Locations Discretionary W arning WARNING • Never operate this A TV on HILLS steeper than 25 de grees 25 ° . T o prevent fli p-over on hilly terrain, when going up or down, use throttle and brakes gradually . • REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. T o prevent flipover , av[...]

8 SAFETY Safety Decals and Locations “No P asseng er” W arning WARNING NEVER ride as a passenger . P assengers can cause a loss of control, resulting in SEVERE INJURY or DEA TH. Age 16 W arning WARNING Operating this A TV if you are under th e age of 1 6 increases yo ur chance of severe injury or d eath. NEVER operate this A TV if you are under[...]

9 SAFETY Safety Decals and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. T o prevent serious injury , do not operate vehicle with gu ard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engi ne RPM, which can result in serious in jury or[...]

10 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a n A TV . W ear protective clothing for comfort an d to reduce the ch ance of injury . Helmet W ea ring a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in [...]

11 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 goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make s[...]

12 SAFETY Operator Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. WA R N I NG F ailure to follow the warnings contained in this manual can result in severe injury or death. A P olaris A TV i s not a toy and can be haza rdous to operate. This vehicle h an- dles differently[...]

13 SAFETY Operator Safety Safety T raining A TV safety training is a top priority for Polaris. Wh en you purchased your new A TV , your dealer instructed you on the authorized A TV RiderCourse sm availa ble to you and y our e ligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and y[...]

14 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safe ty alert symb ol , on your vehicle or in this manual, alerts you to the potential for in jur[...]

15 SAFETY Operator Safety • Read this manual and all labels carefully , and follow the operating procedures described. • Never operate an A TV without prop er instruction. T ake a training course. Purchasers of a new Polari s A TV and their eligible family members are entitled to take the A TV RiderCourse sm . Contact A TV Enrollment Express at[...]

16 SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfa- miliar terrain. Be alert to changing terrain conditions. • Never operate on excessively ro ugh, slippery , or loose terrain. • Always follow proper turning proce dures as de scribed in this manual. Practice turning at low speeds befo re attempting t[...]

17 SAFETY Operator Safety • Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedu res when operatin g over obstacles as described in this manual. • Always be careful of skidding or sliding. On slip pery surfaces like ice, travel slowl[...]

18 SAFETY Operator Safety FOR MORE INFORMA TION ABOU T A TV SAFETY , call the Con- sumer Product Safety Commission a t 1-800-638- 2772, or visit www .cpsc.gov , visit www .atvsafety .org, or call P olaris at 1- 800-342- 3764. Equipment Modifications W e are concerned for the safety of our customers and for the general public. Therefore, we strongly[...]

19 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating this A TV witho ut proper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increase d if the operator does n ot know how to operate the A TV properly in different situ ations and on different types of terra in. HOW TO A VOID THE HAZARD Beginning and inexperi enced oper[...]

20 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Carrying a pa ssenger on an A TV . WHA T CAN HAPPEN Carrying a passenger g reatly reduces the oper- ator's ability to balance and control the A T V , which could cause an accident and injury to the operator and/or passenger . HOW TO A VOID THE HAZARD Never carry a passeng er . The pu rpose[...]

21 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating this A TV on p ublic streets, roads o r highways. WHA T CAN HAPPEN The A TV could collide with anothe r vehicle. HOW TO A VOID THE HAZARD Never operate the A TV on any public stre et, road or highway , in cluding dirt and gravel roads. In many states it's illegal to operate A TVs[...]

22 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating the A TV after consuming alcohol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drug s could seri- ously affect operator judgment. Rea ction time may be slower and operator balance and per- ception could be affected. Consuming alcohol and/or drugs before or while operating a[...]

23 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHA T CAN HAPPEN Attempting stunts increa ses the chance of an accident, including an overturn. HOW TO A VOID THE HAZARD Never attempt wheelies, ju mps, or other stunts. Avoid exhibition driving. WA R N I NG POTENTIAL HAZARD F ailure to inspe ct the [...]

24 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHA T CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejecti on from the A TV . If the operator's foot is not firmly planted on the footres[...]

25 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD F ailure to use extra caution whe n operating on excessi vely rough, slip - pery or loose terrain. WHA T CAN HAPPEN Operating on e xcessively roug h, slip- pery or loose terrain could cause loss of traction or loss of control, which could result in an accident or over- turn. HOW TO A VOID THE H[...]

26 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating on e xcessively ste ep hills. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZARD Never operate on hills too steep for the A TV or for your abi lities. Never operate th e A TV on h ills steeper than 25 degrees. WA R N I NG POTENTIAL HAZARD Climbing hills improperly . W[...]

27 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD T raveling dow nhill improperly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual . NOTE: A special technique is required whe n brakin[...]

28 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Stalling, rolling backwards or improp erly dis- mounting while cl imbing a h ill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZARD Maintain steady speed when climbing a hill . If all forward speed is lost: Keep your weight uphill. Apply the brakes. Lock the parking brake wh[...]

29 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Improperly operating over obstacl es. WHA T CAN HAPPEN Operati ng over obst acles coul d cause loss of cont rol or over turn. HOW TO A VOID THE HAZARD Before operating in a ne w area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unav[...]

30 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating the A TV through deep or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of tracti on and loss of control, which co uld lead to an accident o r overtu rn. HOW TO A VOID THE HAZARD Avoid operating the A TV through deep or fast-flowing water . If it's unavoidabl[...]

31 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Operating this A TV wi th improper tires, or with improper or uneven tire pres- sure. WHA T CAN HAPPEN Use of improper tires, or operation of the A TV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO A VOID THE HAZARD Always use the size and type of tires s[...]

32 SAFETY Operator Safety WA R N I NG POTENTIAL HAZARD Overloading the A TV or carrying/towi ng cargo improperly . WHA T CAN HAPPEN Overloading and towi ng can cause cha nge s i n vehicle handl ing, which could lead to loss of control or an accident. HOW TO A VOID THE HAZARD Never exceed the stated load capacity for this A T V . Cargo should b e pr[...]

33 SAFETY Operator Safety WA R N I NG Operating a da maged A TV can re sult in an accident w ith seri ous injury or death. Afte r any overtu rn or accident , have a qualified se rvice dealer inspect the entire ma chine for possibl e damage, includin g (but not limite d to) brakes, throttle and st eering systems. WA R N I NG Safe operation of th is [...]

34 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse spee d limiter syst em.T o gain additional power while backing, depress the override switch. NOTE: The override sw itch also allows acti vation of All Wheel Drive in reverse, if the AWD switch is on. This switch is also used to toggle through t[...]

35 FEA T URES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the e ngine quic kly . The engine will not start o r run when the switch is of f. NOTE: Both the mai n switch and the engine stop switch will shut off all electri- cal power to the vehi cle, inclu ding li ghts. Main K ey Swit[...]

36 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle move- ment are contro lled by pressin g the throttle lever . The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This A TV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck t[...]

37 FEA T URES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activ ated disc type brake s that ar e activat ed by on ly one lever . Always test brake lever travel and master cylinder fluid level befo re riding. When squeezed, the lever should feel firm. Any sp[...]

38 FEA TURES AND CONTROLS Pa r k i n g B r a k e Locking the P arking 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 pa rking brake lock, squeeze and release the brak[...]

39 FEA T URES AND CONTROLS Auxiliary F o ot Brake The auxili ary brak e system is intend ed to be used as a backup for the main brake system. Should the main system fail, use the auxilia ry foot brake. The auxili ary foot b rake is located on the inside of the right footrest. Operate this brake with your right foot. NOTE: If the rear wheels slide w[...]

40 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 50 for correct ch oke and throttle settings during start- ing. Fu e l T a n k C a p Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gaso- line with a minimum pump octane number of 87=(R+ M [...]

41 FEA T URES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the v ehicle. H: High Gear N: Neutral R: Reverse Whenever the A TV is left unattended, always place the transmission in gear and lock the parking brake. CA UTION Shifting gears with the e ngine speed a bove idle or while t[...]

42 FEA TURES AND CONTROLS Recoil Starter If the battery is too weak to start the engin e, use th e recoil s tarter . Follow the starting procedures on page 50, c ranking th e engine with the recoil starter instead of the main key switc h. 1. Grasp the recoil starter rope handle tightly . 2. Pull slowly so you can feel the engine strokes. NOTE: The [...]

43 FEA T URES AND CONTROLS All Wheel Drive (A WD) System (4X4 Models) The Al l Wheel Driv e system is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times. When the switch is on A WD, the A TV is in all wheel drive and the A WD indicator light in the instrument cluster will be on. When in A WD, the d[...]

44 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in mile s as well as hours of operation. It also includes a reverse speed limiter function that limits the A TV's speed to approximately 7-9 mph. Refer to [...]

45 FEA T URES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 3 seconds at start-up. 1. Gear Indicator - This indicator displays gear shifter position. N = Neutral (Green) R = Reverse (Amber) 2. Engine Hour Display Indicator 3. Speedometer [...]

46 OPERA TION F uel Safety WA R N I NG Gasoline is highly flammab le and exp losive under certain conditions. • Always exercise extreme cautio n whenever hand ling gasoline. • Always refuel with the engine stopped, and outdo ors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area whe re refueling is[...]

47 OPERA TION Break-In P eriod The break-in period for your new Polaris A TV is the first ten hours of operation, or the time it takes to use the first two full ta nks of gasoline. No single action on your part is as important as foll owing the proce- dures for a proper break-in. Careful treatment of a new engine and drive components will result in[...]

48 OPERA TION Break-In P eriod Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 40. 2. Check the oil level on the dipstick. See page 75. Add oil if neces- sary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en area t hat allows room to famil- iarize yourself with vehi cle ope[...]

49 OPERA TION Pre-Ride Checklist WA R N I NG If a proper inspection is not done befor e each u se, severe i njury or dea th could result. Always inspect the vehicl e before each use to ensure it's in proper operating conditio n. Item Remarks P age Brake system/lever travel Ensure proper operation 37 86 Brake fluid Ensure proper level 84 Auxili[...]

50 OPERA TION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock th e parking b rake. NOTE: The starte r interl ock will prevent the engine from starting if the trans- mission is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. Sit on the vehicle. NOTE: Do not use the ch[...]

51 OPERA TION Starting the Engine 8. T urn the ignition key past the ON position to engage t he starter . Activate the starter for a maximum of five seconds, releasing the key when th e engine starts . 9. If the engine do es not start, return the key to the OFF po sition and wait five seconds before attemptin g to start again. Activate the starter [...]

52 OPERA TION Hauling Cargo Y our A TV has been designed to carry or tow a certain amount of load. Always read and understand the load di stribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifi - cations section of the owner's manual and on the safety decals. Car go weight sh ould be evenly di s[...]

53 OPERA TION Hauling Cargo WA R N I NG Hauling cargo improperly can alter vehicle ha ndling an d may cau se loss of control or brake instability and result in seri ous injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALL OW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO . CARGO WEIGHT DISTRIBUTI ON should b[...]

54 OPERA TION Driving Safely Driving Procedures 1. W ear protective ridin g gear . See page 10. 2. Sit upright with both feet on th e foo trests and both hands on the handlebars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check you r surroundings and determi ne your path of travel. 6. Release the parking [...]

55 OPERA TION Driving Safely T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction sl ightly . T o turn, steer in the directi[...]

56 OPERA TION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather , follow these precautions: 1. Slow down wh en enter- ing slippery areas. 2. Engage A WD before wheels begin to lose traction. 3. Maintain a high level of alertness, reading the trail and av[...]

57 OPERA TION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum ). 3. Keep both feet on the footrests . 4. Shift your weight uphill. 5. Procee d at a steady rate of spee d and throttle op ening. 6. Remain alert and b e prepared t o take emer gency action[...]

58 OPERA TION Driving Safely Driving on a Sidehi ll (Sidehilling) Sidehilling can be dangerou s and should be avoided if at all possible. If you encounter a situation where si dehilling is necessary , follow these precautions: 1. Slow down. 2. Shift your weight uphill. 3. Keep your feet on the footrests. 4. S teer slightly into the hill to maintain[...]

59 OPERA TION Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Shift your weight uphill. 2. Drive straight downhill. 3. Slow down. 4. Squeeze the brake lever gradua lly . NOTE: Before operatin g your A TV , learn how to use the auxilia ry brake for emergency situations (if single-lever bra kes become inoperab le).[...]

60 OPERA TION Driving Safely T urning Around 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. 8 ft. (2.4 m)[...]

61 OPERA TION Driving Safely T urning Around on a Hill (K - T urn) 1. S top and lock the parking brake while keepin g body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hi cle, or on the left if the vehi- cle is poin ting straight u phill. 4. S taying uph ill of the vehicle, tu[...]

62 OPERA TION Driving Safely Driving Through W ater Y our A TV can operate through wa ter with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating t hrough water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual in clines. 3. Proceed sl owl[...]

63 OPERA TION Driving Safely Driving Through W ater After running the vehicl e in water , it's criti cal to have it serviced as out- lined in the maintenance chart. See page 68. The following areas need special attention: engine oil, transmi ssion oil, front and rear gearcases, and all grease fittings. NOTE: Avoid operatin g the vehicle throug[...]

64 OPERA TION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for ha zards such as logs, rocks and low hanging branches. WA R N I NG Severe injury or death can result if your vehicle comes in contact with a hid- den obstacle. Not all obstacles are immediately vis[...]

65 OPERA TION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehi cle. 2. Always avoid bac king downhill . 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . NOTE: Y our Polaris A[...]

66 OPERA TION Driving Safely P arking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Always block the rear wh eels on the downhil l side. 5. T urn the fuel valve off.[...]

67 EMIS SION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A . Y our Polaris vehicle has a spark arrestor that was tested and qua[...]

68 MAINTENANCE P eriodic Mai ntenance Char t Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Insp ection, adjustment and lubrication of important components are explained in the periodic ma intenanc e chart. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals th[...]

69 MAINTENANCE P eriodic Mai ntenance Char t Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warrant y but may af fect emissions.) Q Have an authorized Polaris dealer perform these services. WA R N I NG Imp[...]

70 MAINTENANCE P eriodic Mai ntenance Char t Perform all services at whichever main tenance interval is reached 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. Item Maintenance Interval (whichever comes first) Remarks Hours Cal[...]

71 MAINTENANCE P eriodic Mai ntenance Char t Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc. Carburetor float bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage Q E Throttle Cable/ ETC Switch 50 H 6 M 500 (800)[...]

72 MAINTENANCE P eriodic Mai ntenance Char t 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. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q Clutches (drive and driven) 100 H 12 M 1000 (1600) Insp[...]

73 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart be ginning on page 68. Items not listed in the chart should be lubr icated at the General Lubrication interval. Item Lube Method Engine Oil Polaris Premium 4 Synthetic 0W -50 See page 74. Brake Fluid DOT 4 Only See page 84[...]

74 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Perfo rmance Synthetic 4-S troke (PS-4) 0W -50 oil for this engine. PS-4 is a fully synthetic, high performance, multi-viscosity oil designed to prov ide the ultimate in lubrication per- formance and protection. Oil may need to be changed more fre quently if Polaris oil is [...]

75 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the A TV . 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock th e parking b rake. 4. S tart the engine. Allow it to idle for 30 seconds. Sto p the engine. 5. Remove the dipstick . W ipe it dry with a clean c[...]

76 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 68. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock th e parking b rake. 4. S tart the engine. All ow it t[...]

77 MAINTENANCE Oil and Filter Change 1 1. Place towels under the oil filter . Using an oil filter wrench, turn the filter counterclockwise to remove it. 12. Clean the filter sealing area on the engine. 13. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition. 14. Install the new oil filter . After the filter contacts the [...]

78 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginnin g on page 68. Maintain the oil level at the bottom of the fill plug hole. See page 1 19 for the part numb ers of Polaris products. The fill plug is located on the left side of the A TV , under the rear f[...]

79 MAINTENANCE T ransmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Check the oil level. 6. Add oil as needed. Do not overfill. 7. Reinstall the fill plug. T orque to specification. See page 78 for reco m- mendations.[...]

80 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Place a drain pan u nder the gearcase. 6. Remove the drain plug. Use a 15 mm wrench. 7. Allow the oil to drain completely . 8. Clean and reinstall th[...]

81 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Ch art beginning on page 68. W e recommend the use of Polaris Premiu m Demand Drive Hub Fluid. Use of other oils may result in improper operation of compo- nents. See page 1 19 for the part numbe[...]

82 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Check the oil level. 6. Add the recomme nded oil as needed to bring the level to the bottom of the fill hole threads. 7. Re[...]

83 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Place a drain pan under the gearcase. 6. Remove the drain plug. Use an 1 1 mm wrench. 7. Allow the oil to drain completely[...]

84 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride . Always maintain brake fluid at th e recommended level. Do not overfill. If the fluid level is low add DOT 4 brake fluid only . See page 1 1 9 for the part numbers o f Polaris prod ucts. Under normal operation, the diaphr agm extends into the reservoir as f[...]

85 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar . Main- tain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder . Do not over- fill. 1. Position the vehicle on a level surface. Make sure the handleba rs are straight. 2. V iew the fluid level through the indicat or win- dow (eye) o[...]

86 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the hand lebar . The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommende d to keep the brake system in good operating condition. Check more ofte[...]

87 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. 1. Place the handlebars in a straight-ahead position. 2. Place stands in front of the vehicle, per- pendicular to the rear tires. 3. T ie an elas tic string around th e stand[...]

88 MAINTENANCE Steering Assembly The steering assemb ly of the A TV should be check ed periodically for loose nuts and bo lts. If loose nuts and bolts are fo und, see your Polaris dealer for service before ope rating the vehicl e. Side P anel Removal 1. Remove the seat. 2. Grasp the top of the side panel and pull it outward to remove it. F ootwell [...]

89 MAINTENANCE Tires Refer to the specifications section beginning on page 1 24 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. F ront Wheel Hub Tightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operati ons. All se[...]

90 MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Loosen the wheel nuts slightly . 5. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 6. Remove the wheel nut s. 7. Remove the wheel.[...]

91 MAINTENANCE Tires Wheel Installation 1. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts finger tight. 3. Lower the veh icle to the ground . 4. T orque the wheel nuts to specification. Wheel Nut T orque Sp ecifications Check the[...]

92 MAINTENANCE Air Filter/Breather Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Remove the seat. 5. Release the air box cover clip s, and remove the air bo x cover . 6. Remove the air filter . 7. Remove the sleeve from the filter . 8. W ash the sleeve in soapy wate r , then r[...]

93 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in neutral. 3. Lock th e parking b rake. 4. Measure t[...]

94 MAINTENANCE Lights When servicing a ha logen lamp, do n't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlamp Replacement 1. T urn the back of the headlight harness counterclockwi se and pull the harness assembly away from the headlight assembly . 2. Remo[...]

95 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the h ousing before storing the vehicle. Make sure the hous- ing is completely dry before reinstalling the drain plug. 1. Place the transmission in gear . 2. Lock th e parking b rake. 3. S top the engine. 4. Remove the drain screw on[...]

96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifi cations section beginn ing on page 1 24 for the recom- mended spark plug type and gap for yo ur vehicle. T orque spark plugs to specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operat ion. Check the spark plug firing end condition after the [...]

97 MAINTENANCE Spark Plugs Spark Plug Inspection 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. V erify that the gap is at specification before installation. 5. Reverse the procedure for spark plug installation. T o rque to specification. Spark Plug Condition Normal Spar k Plug The normal insulator tip is gray [...]

98 MAINTENANCE V ehicle Immersion If it's impossible to take your A TV to a de aler before starting it, follow the steps outlined below . 1. Move the vehicle out of the water . 2. T urn the fuel valve off. 3. Check the air box. If water is present, dry the air bo x and replace the filter with a new filter . 4. Remove the spark p lug. 5. Loosen[...]

99 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur ge acc umulated carbon from the exha ust p ipe/muffler . 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock th e parking b rake. 4. Remove the arrestor clean-out plug from t he bottom of the muf fler . 5. S tart the engine. 6. Quick[...]

100 MAINTENANCE PVT System WA R N I NG F ailure to comply with the instru ctions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce i ts strength so that a failu re may occur at a high speed. The PVT system has been precision ba lanced. Any modification will cause the syst em to [...]

101 MAINTENANCE PVT System PVT Drying There m ay be so me instan ces when water is accidently ingested into the PVT system. Use the following instructions to dry it out befo re operating. 1. Move the vehicle out of the water . 2. Remove the P VT drain plug. Use a 17 mm w rench, a f lat scre w- driver , or the spa rk plug wrenc h. 3. Allow the water[...]

102 MAINTENANCE Battery Y our A TV may have either a sealed battery , which requires little mainte- nance, or a conventional battery . A sealed ba ttery can be identified by its flat covers on the top of the battery . A conventional battery has six filler caps on the top of the battery . Conventional Battery Always keep battery terminals and connec[...]

103 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock th e parking b rake. 3. Open the front cover . 4. Disconnect the battery hold- down strap. 5. On conventional batteries, remove the ba ttery vent tube. 6. Disconnect the black (nega- tive) battery ca ble first. 7. Disconnect the red (p osi- tive) battery ca ble last[...]

104 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinder vehicle performance. Follow the battery charging instructio ns on page 106 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the batte ry in[...]

105 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ge d, and store it out of the sun in a cool, dry place. Check battery voltage each month during st orage and recha rge as needed to maintain a full char ge. NOTE: Batter[...]

106 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to preven t damage from leak- ing or spilled ele ctrolyte during cha r ging. Se e page 103. 2. Char ge the battery with a charging output no lar ger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to [...]

107 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top o f battery ) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required[...]

108 MAINTENANCE Cleaning and Storage W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various componen ts. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing clot h, cleanin[...]

109 MAINTENANCE Cleaning and Storage W ash ing the V ehicle If a high pressure water system is u sed for clea ning (n ot recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A v oid direc ting the water stream at the follow- ing items: • Wheel bearin gs • T ransmission seals •B r a k e s[...]

110 MAINTENANCE Cleaning and Storage 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. NOTE: Chrome whee ls exposed to road salt (or sa lt in the air in coastal areas) are more su sceptible to corrosion if no t properly cle[...]

111 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. See page 108. Stabilize the F uel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel T reatment or Polaris Fuel S tabilizer . Follow the instructions on th e container for the recomm ended amount. NOTE: Carbon [...]

112 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as reco mmended in th e Periodic Maintenance Chart beginning on page 6 8. • Demand drive unit (front gearcase) • T ransmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) F og the Engine 1. T rea[...]

113 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommende d in the Periodic Maintenance Chart beginn ing on page 68. Battery Storage See pages 105-106 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV with[...]

114 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 th e parking b rake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to prev en t loss during transporting. 7. Always tie the frame of the A TV to[...]

115 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Spring Adjustments The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to incr ease or decrease spring tension. Always ad just both sides equally . NOTE: Accessory springs are availab le through your Polaris dea[...]

116 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. 1. Loosen the fo ur handlebar b olts. 2. Adjust the handlebar to the desired heigh t. NOTE: Be sure the han dlebars do not contact the gas tank or any other part o f the machine when turned fully to the left or right. 3. T orque the front two bolts to 10-12 ft. lbs. (14[...]

117 ADJUSTMENTS Carburetor Y our Polaris A TV is calibrated at the fa ctory 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 (1 800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea c[...]

118 ADJUSTMENTS Throttle Cable F reeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the en d of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16"[...]

119 POL ARIS PRODUCTS Pa r t N um b e r Description Engine L ubricant 2870791 F ogging Oil (12 oz. Aerosol) 2874865 P erformance Syn thetic 4-St roke (PS-4) 0W -50 Oil (qt.) 2874866 P erformance Syntheti c 4-Stroke (PS-4) 0W -50 Oil (gal.) Gearcase / T ra nsmission Lub ricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium A[...]

120 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a picku p or tall trailer in high rang e Use low range (if equipped). Starting out going up a steep in cline Use low range (if equipped) or turn around using the K- turn (see page 60). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or u se low range[...]

121 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , F a ils to Start Engine Backfires Possible Cause Solution Blown fuse Replace fuse Low battery voltage Rechar ge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cause Solu[...]

122 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommen ded fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Possible Cause Solutio[...]

123 TROUBLESHOOTING Engine Stops or Loses P ower Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace wi th new fuel Overuse of choke Ins pect, cl ean a nd/or replace spark plugs Fouled[...]

124 SPECIFICA TIONS * Based on EU Directive 76/432/EC Hawkeye 2X4 Gross V ehicle W eight 930 lbs. (422 kg) Dry W eight 525 lbs. (238 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmission Oil 15.2 oz. (450 ml) Demand Drive Flui d 5 oz. (148 ml) Front Rack Capacity 70 lbs. (32 kg) Rear Rack Capacity 100 lbs. (45 kg) Hitch[...]

125 SPECIFICA TIONS Jetting Chart Clutching Ch art Hawkeye 2X4 T ires/Pressure, Front 22x7-12 / 5 psi T ires/Pressure, Rear 22x10-12 / 5 psi Front Suspension MacPherson strut with 7" (18 cm) travel Rear Suspension Progressive ra te with 8" (20 cm) travel Shock Adjustment CAM Brakes, Front Single-Control Hydraulic Disc Brakes, Rear Single-[...]

126 SPECIFICA TIONS * Based on EU Directive 76/432/EC Hawkeye 4X4 Gross V ehicle W eight 930 lbs. (422 kg) Dry W eight 550 lbs. (250 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmission Oil 20.3 oz. (600 ml) Demand Drive Flui d 5 oz. (148 ml) Front Rack Capacity 70 lbs. (32 kg) Rear Rack Capacity 100 lbs. (45 kg) Hitch[...]

127 SPECIFICA TIONS Jetting Chart Clutching Ch art Hawkeye 4X4 Drive Ratio, Fron t 3.6:1 Drive Ratio, Final 15.18:1 T ires/Pressure, S tandard models Front 22x7-12 / 5 psi (34.5 KPa) Rear 22x10-12 / 5 psi (34.5 KPa) T ires/Pressure, LE models Fr on t 23x7-12 / 5 psi (34.5 KPa) Rear 23x10-12 / 5 psi (34.5 KPa) Front Suspension MacPherson strut with [...]

128 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s. This warranty co[...]

129 W ARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF W ARR ANTIES AND RE MEDIES The Polaris l imited warranty e xcludes any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This warranty also does not cover any A T[...]

130 W ARRANTY ALL IMPLIED W ARRANTIES (INCLU DING BUT NOT LIMITED TO THE IMPLIED W ARRA NTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. PO LARIS FUR THER DI SCLAIMS ALL EXP RESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY . Some st ates do not al low limi- tations[...]

131 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER V ICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LO CA- TION. This policy does n ot apply to vehicles that have received authorization for export from Polaris Industries. De[...]

132 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally pur chased, a ll warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you hav[...]

133 W ARRANTY U.S.A . EP A Emiss ions Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limit ed warranty is in addition to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with th[...]

134 MAINTENANCE L OG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

135 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

137 INDEX I Idle RPM Adju stment . . . . . . . . . . . 117 Immersion . . . . . . . . . . . . . . . . . . . . . 98 Instrument Cluste r . . . . . . . . . . . . 44-45 J Jetting Chart, 2X4 . . . . . . . . . . . . . . 125 Jetting Chart, 4X4 . . . . . . . . . . . . . . 127 K Key Switch . . . . . . . . . . . . . . . . . . . . 35 K-Turn . . . . . . . . . .[...]

136 INDEX A Accessories . . . . . . . . . . . . . . . . . . 113 Age Restrictions . . . . . . . . . . . . . . . . 12 Air Filt er . . . . . . . . . . . . . . . . . . . . . 92 All Whe el Drive Switch. . . . . . . . . . 35 All Wheel Drive Syst em . . . . . . . . . 43 AWD Switch . . . . . . . . . . . . . . . . . . 43 AWD System . . . . . . . . . . . . .[...]

138 INDEX T Taillight . . . . . . . . . . . . . . . . . . . . . . 94 Throttle Cable Freepl ay . . . . . . . . . 118 Throttle Lever . . . . . . . . . . . . . . . . . 36 Tire Tread Depth . . . . . . . . . . . . . . . 89 Tires Front Wheel Hub Tightening . . 89 Tread Depth . . . . . . . . . . . . . . . 89 Wheel Installat ion . . . . . . . . . . 91 Whee[...]