Polaris 300 2X4 manual

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1 WELCOME Thank you for purcha sing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an ex citing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • Quadricycles • RANGER utility vehicles • V ictory motorcycles Always follow the instructions and recomme[...]

2 POLARIS and POLARIS TH E W A Y OU T are regist ered trademarks of Pola ris 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 publication. Due to constant improvements in the design and quality of production components, some minor discre[...]

3 T ABLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F eatures and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Emission Control Systems . . . . . . . . . . . . . [...]

4 KNOW Y OUR VEHICLE As the operator of the vehicle, y o u are responsible for your personal safety , the safety of others, and the protection of our environment. Read and understand your owner's manu al, which includes valuable info rma- tion about all aspe cts of your vehicle, incl uding safe operati ng proce- dures. Ride r esponsibly . Know[...]

5 SAFETY Operator Safety The following signal words and symbol s appear throughout this man ual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their me anings befor e r eading the manual . The safety ale rt symbol , on your vehicle or in thi s manual, alerts you to the potential for injur[...]

6 SAFETY Operator Safety Safety T raining When you purchased your new Quadricycle, your dealer offered a hands-on safety training course. Y ou were also p rovided with printed materials that explain safe operatin g procedures. Review this informa- tion on a regular basis. If you purchased a used Polaris Quad ricycle from a party other than a Polari[...]

7 SAFETY Operator Safety Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle. Never operate a Quadricycle wit hout prop[...]

8 SAFETY Operator Safety Always wear an approved helmet that fits properly . Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume al cohol or drug s before or while operating a Quadricycle. Never operate at excessive speeds. T ravel and turn at speeds appro priate for the terrain, visibility , oper[...]

9 SAFETY Operator Safety Always inspect your Quadricycle before each use to verify that it's i n safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 49. Keep both hands on the h andlebars. Keep your feet on the footrests. Always travel slowly when operating on unfamiliar terrain. Use ext[...]

10 SAFETY Operator Safety If a Quadricycle ha s been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not li mited to) brake, throttle and st eering systems. Never operate on hills too steep for the Quadricycle or fo r your abilities. Practice on smaller hills before at[...]

11 SAFETY Operator Safety Always follow the procedures outl ined in this manual for braking if you stall or roll backwards whil e climbing a hill. Never back down a hill. See page 26. Always follow the procedures outl ined in this manual for operating over obstacles. See page 21. Always follow the procedures outl ined in this manual for operating o[...]

12 SAFETY Operator Safety Always follow the procedures outl ined in this manual for driving in reverse. See page 31. Always use the size and type of tires specified for your Quadricycle. Maintain the proper tire pressure. Never modify a Quadricycle through improper installatio n or use of accessories. Never exceed the stated load capaci ty for your[...]

13 SAFETY Operator Safety Never operate the Quadricycle on a frozen body of water . Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control, accident, and/ or injury . Avoid sudden turns or swift movement of the handlebars. Always remove the ignition key when the vehicle is n [...]

14 SAFETY Safety Decals and Locations W arning decals have been placed o n the vehicle for your protection. Read and follow the instructions on each decal carefully . If a decal becomes illegible or comes of f, contact your Polaris dealer to purchase a replacement. Replacement safety deca ls are provided by Polaris at no charge. The part number is [...]

15 SAFETY Safety Decals and Locations “No P assenger” W arning WARNING NEVER ride as a passenger . P assengers can cause a loss of control, resu lting in SEVERE INJURY or DEA TH. Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KP a): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAP ACITY (Gross V ehi cle We ight) INCLUDING MACHINE, DRIVER AND CAR[...]

16 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury . Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Ca nada bear a U.S. Dep artment of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE m[...]

17 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 goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make [...]

18 SAFETY Driving Safely Driving Procedures 1. Sit upright. Kee p your feet on th e footrests. K eep both hands on the handlebars. 2. Apply the brake s. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check your surro undings and determine your path of travel. 6. Release the brakes. 7. Slowly squeeze the throt[...]

19 SAFETY Driving Safely T urning the V ehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Acti- vate the right signal before a right turn. 2. Steer i n the direction of the turn, leaning your upper b ody to the inside of the turn while supporting you r weight on the out[...]

20 SAFETY Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as we t trails, gravel, snow or ice, follow these precautions: 1. Slow down before driv ing onto slippery surfaces. 2. Engage A WD before wheels begin to lose traction (4x4 models). 3. Be alert. 4. W atch the trail. 5. A void quick, sharp turns[...]

21 SAFETY Driving Safely Driving Over Obstacles 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. W atch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. A void hazards such as logs, rocks and low branches. A[...]

22 SAFETY Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. Check the terrain carefully . 3. A void hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill. 6. Keep your feet on the fo otrests. 7. Drive at a steady rate of spe[...]

23 SAFETY Driving Safely Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins r olling downhill, never apply engine power . Never apply the brakes aggr essively while r olling backwar ds. Apply the brakes gradually . When fu lly stopped, lock the hydraulic parking brak e. See pa ge 39. Dismount on the uphill s[...]

24 SAFETY Driving Safely Driving on a Sidehi ll (Sidehilling) A void crossing the side of a hill (sid ehilling) if possible. If sidehilling is necessary , follow these precautions: 1. Slow down. 2. A void hills with excessively slippery or loose surfaces. 3. Shift your weight uphill. 4. A void crossing the sides of steep hills. 5. Keep your feet on[...]

25 SAFETY Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Check the terrain carefully . 2. A void hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. A void driving downhill at an angle, which can cause the vehicle to pitch sharply to one side. Drive straight[...]

26 SAFETY 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. 1. Stop the vehicle. Keep your weight uphill. 2. Lock th e hydrau lic parking brake. 3. Leave the transmission in forw ard gear . T urn the engine off. 4. Dismount on the uphill side[...]

27 SAFETY Driving Safely T urning Around on a Hill (K - T urn) 8. Lock the hydraulic parking brake. 9. Remount from the uphill side. Keep your weight uphill. 10. Apply the foot brake. 1 1. With the transmission still in forward, start the engine. 12. Squeeze and release the brake le ver to rele ase the parking brake. 13. Release the foot brake and [...]

28 SAFETY Driving Safely Driving Through W ater Follow these procedures wh en driving through water: 1. Check water depth and cu rrent before crossing. 2. A void operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slo wly , balance your weigh t carefully and avoid sudden movements. Mainta in a slo w and stea[...]

29 SAFETY Driving Safely Driving Through W ater Always follow the procedures outl ined in this manual for driving through water . Never drive throug h deep or fast-flowing water . If your vehicle becomes fully immersed , and it's impossible to take it to a dealer before starting it, follow the steps described on page 85. Have the vehicle servi[...]

30 SAFETY Driving Safely P arking on an Incline A void parking on an incline. If it' s unavoidable, follow these precau- tions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Always block the rear wheels o n the downhill side. 4. T urn the fuel valve of f.[...]

31 SAFETY Driving Safely Driving in Reverse Follow these precautions whe n operating in reverse: 1. A void backing do wn- hill. 2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly . 4. Apply the foot brake lightly for stopping. 5. A void turning at sharp angles. 6. Do not use the override switch un less additi[...]

32 SAFETY Driving Safely Hauling Cargo WAR N I NG Overloading the vehicl e or carrying or towing cargo improperly can alte r vehicle handling and may cause loss of co ntrol or brake instability . Always follow these pr ecautions when haulin g cargo. • Read and understand the load distribut io n warnings listed on the vehicle warning labels. • N[...]

33 SAFETY Driving Safely Hauling Cargo T owing Loads T ow ing is approved OFF-ROAD ONL Y . Operating a Quadricycle/trailer combination on public roads is proh ibited. Do not exceed the maximum capacities when towing. Do not tow an y trailer on a grade steeper than 15 ° . Using an improper hitch or exceeding the maximum tongue weight capa city can [...]

34 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 45 . T o gain additional power while opera ting in reverse, press the override switch before opening th e throttle. This will canc el the reverse speed limit function. NOTE: The override swit[...]

35 FEA TURES AND CONTROLS Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Star t the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position. Engine Stop Switch The engine will not start or run when the swit[...]

36 FEA TURES AND CONTROLS Switches All Wheel Drive Switch (4x4 Models) See page 44 for all wheel drive information. Hazard W arning Switch Push the hazard warning switch to cause all turn indicators to flash simultaneously . Use this feature to alert others of an emergency or other situation requiring caution. T urn Signal Switch Push the toggle sw[...]

37 FEA TURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. Choke The choke assists in starting a cold engine. See page 50. Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the[...]

38 FEA TURES AND CONTROLS Fo o t B r a k e The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with yo ur foot to engage the all-wheel brakes. If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure. Hand Brake Lever The hand br[...]

39 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 PA R K . 2. Squeeze the brake lever toward the handlebar . 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lock, squeeze and release the brake lever . WAR N I NG Operating [...]

40 FEA TURES AND CONTROLS Steering Lock Lock the steering to prevent unauthor ized use or theft of the vehicle. 1. T u rn the handlebars to the full left position. 2. Insert the steering lo ck key and turn it clockwise . 3. Remove the key . 4. Reverse the procedure to unlock the steering. NOTE: Place the steering lock keys in a safe place. The lock[...]

41 FEA TURES AND CONTROLS 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 of 87. Do not use E-85 fuel. F uel V alve The fuel valve is located on the bottom of the fuel tank. Access the fuel valve th rough the right front wheel well. ON: For normal operat[...]

42 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehic le. H: High Gear N: Neutral R: Reverse P: Park Whenever the vehicle is left unattended, always place the transmission in P ARK. The transmission is locked when it’ s in PA R K . CA UTION Shifting gears with the [...]

43 FEA TURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine , use the recoil starter . Follow the starting procedures on page 50, crank ing the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly . 2. Pull slightly until the starter mechanism engages. 3. Pull the[...]

44 FEA TURES AND CONTROLS All Wheel Drive (A WD) System (4X4 Models) The A WD switch may be turned on or off while the vehicle is mov ing. A WD will not engage until engine speed is below 3100 RPM. A WD remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in A WD. If the switch is turned of [...]

45 FEA TURES AND CONTROLS Instrument Cluster The instrument cluster mea- sures distance in kilometers (or miles) as well as hours of oper- ation. It also includes a reverse speed limiter function that lim- its vehicle speed to approxi- mately 1 1-14 km/h. Refer to page 34 for additional informa- tion. Miles/Kilometers T oggle The display in the tri[...]

46 FEA TURES 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 4[...]

47 OPERA TION F uel Safety WAR N I NG Gasoline is highl y flammable and explosive under certain condition s. • Use extreme caution whenever handli ng gasoline. • Refuel with the en gine stopped. Ref uel outdoors or in a well-ventilated area. • Never fill a fuel container while it's on the vehicle. Static electricity between the rack and [...]

48 OPERA TION Break-In P eriod The break-in period for your new Po laris Quadricycle is the first ten hours of operation, or the time it take s to use the first two full tanks of gasoline. No single action on your part will increase the life and perfor- mance of your Quadricycle more th an following the procedu res for a proper break-in. Careful tr[...]

49 OPERA TION Pre-Ride Checklist Item Remarks P age Foot brake Ensure proper operation 38 Hand brake/lever travel Ensure proper operation 38 73 Brake fluid Ensure proper level 70 F ront suspension Inspect, lubricate if ne cessary 58 Rear suspension Inspect, lubricate if necessary 58 Steering Ensure free operation - Tires Inspect condition and press[...]

50 OPERA TION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in PA R K . ____________ __________ ___________ __________ _____________ 3. T urn the fuel valve on. 4. Sit on the vehicle. NOTE: Do not use the choke if starti ng a warm engine. Excessive use of the choke can cause the spark plug to become wet f[...]

51 OPERA TION Starting the Engine 7. T urn the ignition key past the POSITION LIGHTS ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the engine starts. 8. If the engine does not start, release the starter and wait five seconds. 9. Repeat steps 7 and 8 until the engine starts. NOTE: If a[...]

52 EMIS SION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with gover nmental noise level requi rements. Spark Arrestor Y our Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark ar restor re[...]

53 MAINTENANCE P eriodic Maintena nce Chart Maintenance intervals in the following chart are b ased upon average riding conditions and average vehicl e speed of approximately 16 km/h. V ehicles subjected to severe use must be inspected and serviced more frequently . Record maintenance and service in the Maintena nce Log beginning on page 1 19. NOTE[...]

54 MAINTENANCE P eriodic Maintena nce Chart 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. WAR N I NG Impro[...]

55 MAINTENANCE P eriodic Maintena nce Chart 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 Cale[...]

56 MAINTENANCE P eriodic Maintena nce Chart 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) [...]

57 MAINTENANCE P eriodic Maintena nce Chart 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) Inspe[...]

58 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart be ginning on page 53. 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 59. Brake Fluid DOT 4 Only See page 70[...]

59 MAINTENANCE Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Ch art beginning on page 53. Al ways change the oil filter whenever changing oil. Cha nge the oil more often if the vehicle is routinely subjected to: • operation in dusty or wet conditions • operation when [...]

60 MAINTENANCE Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Star t the engine. Allow it to idle for 30 seconds. 4. S top the engine. 5. Remove the dipstick. W ipe it dr y with a clean cloth. 6. Reinstall the dipstick completely . 7. Remove the dipstick and ch eck the oil level. Add oil as n[...]

61 MAINTENANCE Oil and Filter Change 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. S tart the engine. Allow it to idle for two minutes. 4. S top the engine. 5. Clean the area around the drain plug. 6. Place a drain pan under the vehicle. 7. Remove the drain plug. Use a 6 mm Allen wrench . 8. Drain the oil. 9. Cl[...]

62 MAINTENANCE Oil and Filter Change 1 1. P lace 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[...]

63 MAINTENANCE Oil and Filter Change 15. Remove the dipstick. 16. Add the recommend ed oil. See page 59. 17. Reinstall the dipstick. 18. Star t the engine. Allow it to idle for two minutes. 19. Stop the engine. 20. Check for oil leaks. 21. Check the oil level. Add oil as needed. Main- tain the oil level in the safe range. Do not overfill. 22. Reins[...]

64 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on p age 53. Use the recommended oil. Maintain the oil level at the bottom of the fill plug hole. See page 107 for th e part numbers of Polaris products. The fill plug is located on the left side of the[...]

65 MAINTENANCE T ransmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. Use a 15 mm wrench. 4. Check the oil level. 5. Add the recommend ed oil as needed . Do not overfill. 6. Reinstall the fill plug. T o rque to specification. See page 64.[...]

66 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. Use a 15 mm wrench. 4. Place a drain pan und er the gearcase. 5. Remove the drain plug. Use a 15 mm wrench. 6. Allow the oil to drain completely . 7. Clean and reinstall the drain plug. T orque to spec[...]

67 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at th e inter- vals outlined in the Periodic Maintenance Chart beginning on page 53. Use the recommended fluid. Use of other fluids may result in improper operation of com- ponents. See page 107 fo r the part numbers o f Polaris prod - ucts. Maintain [...]

68 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. Use an 8 mm Allen wrench. 4. Check the fluid level. 5. Add the recommend ed fluid as needed. 6. Reinstall the fill plug. 7. T orque to specification. See page 67.[...]

69 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the fill plug. Use an 8 mm Allen wrench. 4. Place a drain pan under the gearcase. 5. Remove the drain plug. Use an 1 1 mm wrench. 6. Allow the oil to drain completely . 7. Clean and reinstall the[...]

70 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended leve l. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indi cate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are wo rn and[...]

71 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handle- bar . Maintain the fluid level 6 mm below the top ed ge of the master cylinder . Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. V iew the fluid level through the indicator win- dow (eye) on the top of the [...]

72 MAINTENANCE Brake Fluid Foot Brake The brake fluid reservoir is located near the foot brake. Maintain the fluid level between the minimum an d maximum marks. Do not overfill. Minimum Maximum[...]

73 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by apply- ing either the hand brake or the foot brak e. Both brak e system s are se lf- adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition. Check more often if brakes are used heavily under normal opera[...]

74 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent is 3-6 mm toe out. 1. Place the handleba rs in a straight-ahead position. 2. Place stands in front of the vehicle, per- pendicular to the rear tires. 3. T ie an elastic string around the sta nds, making sure the string[...]

75 MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, se e your Polaris dealer for service before operating the vehicle. 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 Removal 1. Rem[...]

76 MAINTENANCE Tires Refer to the specifications section beginning o n page 1 12 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 3 mm or less. F ront Wheel Hub Tightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operations. All service must b[...]

77 MAINTENANCE Tires Wheel Removal/Installation 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Loosen the wheel nuts slightly . 4. Place a suitable stand under the footrest frame to raise the whee l slightly off the ground. 5. Remove the wheel nut s. 6. Remove the wheel. 7. Place the wheel on the hub. 8. Install [...]

78 MAINTENANCE Air Filter/Breather Filter Always clean and replace the air and br eather filters at the intervals out- lined in the Periodic Maintena nce Chart beginning on page 53. 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the seat. 4. Release the air box cover clips, and remove the air box cover . 5[...]

79 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 7.6 m from a wall. 2. Place the transmission in P ARK. 3. Measure the distance from the floo r to the cente[...]

80 MAINTENANCE Lights Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not 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. Hold the plastic part of the lamp. 1. Place the transmission in P ARK. 2. Open the front rack cover . 3. Remove the pl[...]

81 MAINTENANCE Lights T aillight/Brakelight Lamp Replacement 1. From the rear of the brake- light, remove the two screws holding the lens cover in place. Remove the lens cover . 2. Remove the lamp and replace it with a new lamp. 3. T est the light for proper operation. 4. Reinstall the lens cover . T urn Signal Lamp Replacement 1. Place the transmi[...]

82 MAINTENANCE Recoil Housing Always drain the recoil ho using after operating the vehicle in wet conditions. Drain the ho using before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug. 1. Place the transmission in P ARK. 2. S top the engine. 3. Remove the drain screw on the bottom of the recoil housin[...]

83 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginni ng on page 1 12 for the recom- mended spark plug t ype and gap for your vehicle. T orque spark plugs to specification. 1. Remove the left side p anel. See page 75. 2. Remove the spar k plug cap. 3. Use the spark plug wrench to remove the spark plug. Tu[...]

84 MAINTENANCE Spark Plugs Spark Plug Inspection Spark plug condition is i ndicative of engine operation. Check the spark plug firing end condition after the en gine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color . Normal Sp ark Plug The normal insulator tip is tan or brown. T[...]

85 MAINTENANCE V ehicle Immersion If your vehicle has bee n totally submerged in water and it's impossible to have it serviced before further operation, perform the following procedure. 1. Move the vehicle o ut of the water . 2. T urn the fuel valve off. 3. Remove th e spar k plug. 4. Drain any water found in the air box. 5. Loosen the carbure[...]

86 MAINTENANCE V ehicle Immersion 6. T urn the ignition key past the POSITION LIGHTS position to engage the starter . Engage the starter for only 2-3 seconds. 7. T ighten the carburetor drain screw . 8. Dry the spark plug. Reinstall the plug or install a new plug. 9. T orque to specifica tion. 10. T urn the fuel valve on. 1 1. Attempt to start the [...]

87 MAINTENANCE Spark Arrestor Occasionally , the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Pur ge the spark arrestor . 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the arrestor clean-out plu g from the bottom of the muffl er . 4. Star t the engine. 5. Quickl[...]

88 MAINTENANCE PVT System PVT Drying If water is ingested into the PVT system, dry it before operating the vehicle. 1. Move the vehicle o ut of the water . 2. Place the transmission in PA R K . WAR N I NG Do not modify any component of the PVT system. Doing so may reduce its strength so that a failu re may occur at a high speed. The PVT system has [...]

89 MAINTENANCE PVT System PVT Drying 3. Remove the PVT drain plug. Use a 17 mm wre nch, a fl at screw- driver , or the spark plug wrench. 4. Allow the water to drain com- pletely . Reinstall the drain plug. 5. Start the engine. Place the trans- mission in P ARK. 6. Apply varying throttle for 10-15 seconds to expe l the moisture and air-dry the belt[...]

90 MAINTENANCE Battery Y our vehicle may have either a sealed battery , which requires little maintenance, or a conventional battery . A se aled battery can be identi- fied 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 conn[...]

91 MAINTENANCE Battery Battery Removal 1. Place the transmission in P ARK. 2. Open the front cover . 3. Disconnect the battery hold- down strap. 4. On conventional batteries, remove the batte ry vent tube. 5. Disconnect the black (nega- tive) battery cable first. 6. Disconnect the red (posi- tive) battery cable las t. 7. Lift the battery out of the[...]

92 MAINTENANCE Battery Battery Installation 1. Ensure that the battery is fully char ged. 2. Place the battery in th e battery holder . 3. W ith conventional batteries, install the battery vent tube (sealed bat- teries do not have a vent tube). NOTE: The vent tube must be free of obstr uctions and securely installe d. Route the tube away from the f[...]

93 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three month s or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage an d recharge as needed to maintain a full charge. NOTE: Battery c[...]

94 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled electrolyt e during charging. See page 91. 2. Charge the battery with a char ging output no larg er than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.270[...]

95 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow al l instructions carefully . 1. Check the battery voltage with a voltmeter or mul timeter . A fully charged battery will register 12.8 V or higher . 2. If the voltage is less than 12.8 vo lts, recharge the battery at 1.2 amps or less until battery voltage is 12.8[...]

96 MAINTENANCE Cleaning and Storage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various co mponents. High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect[...]

97 MAINTENANCE Cleaning and Storage W ashing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The wate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: • Wheel bearings • T ransmission seals •B r a k e s • C[...]

98 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 wheels exposed to road salt (or salt in the air in coastal areas) are more susce ptible to corrosion if no t properly clean [...]

99 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Se e page 96. Stabilize the F uel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel T reatment or Polaris Fuel Stabilizer . Follow the instructions on th e container for the rec ommende d amount. NOTE: Carbon Cl[...]

100 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change flu ids as recommende d in the Periodic Maintenance Chart beginn ing on page 53. • Demand drive unit (front gearcase) • T ransmission • Brake fluid (change every two years and any time the flui d looks dark or contaminated) Fog the Engine 1. T reat[...]

101 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 53. Battery Storage See pages 93-94 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely su pport the vehicle wi[...]

102 MAINTENANCE T r ansporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in P ARK. 3. T urn the fuel valve of f. 4. Secure the fuel cap, oil cap and seat. 5. Remove the key to prevent loss during transporting. 6. Always tie the frame of the Quad ricycle to the tr ansporting un[...]

103 ADJUSTMENTS Spring Adjustments The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrea se spring tension. Always ad just both sides equally . NOTE: Accessory springs are available throug h your Polaris dealer . Rear Adjuster Fr o n t Adjuster[...]

104 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. 1. Loosen the four h andlebar bolts. 2. Adjust the handlebar to the desired height . NOTE: Be sure the handlebars do n ot contact the gas tank or any other part of the m achine when turned fully to the left or right. 3. T orque the front two bolts to 14-17 N-m, then tor[...]

105 ADJUSTMENTS Carburetor Y our Polaris Quadricycle is calibrate d at the factory for optimal perfor- mance at altitudes ranging from zero to 1800 meters and temperatures of 4 degrees C. or higher . Above 1800 meters the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 300 meter increase in el[...]

106 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 sli de it far enough to ex pose the end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1.6-3.2 [...]

107 POL ARIS PRODUCTS Pa rt N u m be r Description Engine Lubri cant 2870791 Fogging Oil (12 oz. Aerosol) 2874865 Performance Synthetic 4-St roke (PS-4) 0W-50 Oil (.95 l) 2874866 Performance Synthetic 4-St roke (PS-4) 0W-50 Oil (3.8 l) Gearcase / T ransmission Lubricants 2873602 Premium AGL Synthetic Gear case Lubricant (.95 l) 2873603 Premium AGL [...]

108 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range (if equipped). Starting out going up a steep incl ine Use low range (if equipped) or turn around using the K- turn (see page 26). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range (if[...]

109 TROUBLESHOOTING Engine Does Not Rotate Engine Rotates, F ails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge 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 Solution Out of fuel Refuel Clogged fuel va[...]

110 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended 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 Solution [...]

111 TROUBLESHOOTING Engine Stops or Loses Power 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 (if equipped) W ater is present in fuel Replace with fresh rec ommended fuel Old or non-recommended fuel Replac e with[...]

112 SPECIFICA TIONS * Based on EU Directive 76/432/EC Hawkeye 2X4 International Gross V ehicle W eight 4 23 kg Dry W eight 243 kg Fuel Capacity 17 l Engine Oil Capacity 1.9 l T ransmission Oil 450 ml Demand Drive Fluid 148 ml Front Rack Capacity 32 kg Rear Rack Capacity 45 kg Hitch T ongue W eight Capacity 34 kg (Rea r rack capacity a nd tongue wei[...]

113 SPECIFICA TIONS Jetting Chart Clutching Chart Hawkeye 2X4 International T ires/Pressure, Front 22x7-12 / 34.5 KPa T ires/Pressure, Rear 22x10-12 / 34.5 KPa Front Suspension MacPherson strut with 18 cm travel Rear Suspension Progressive rate with 20 cm travel Shock Adjustment CAM Brake, Hand All-wheel hydraulic disc Brake, Foot All-wheel hydraul[...]

114 SPECIFICA TIONS * Based on EU Directive 76/432/EC Hawkeye 4X4 International Gross V ehicle W eight 4 23 kg Dry W eight 250 kg Fuel Capacity 17 l Engine Oil Capacity 1.9 l T ransmission Oil 600 ml Demand Drive Fluid 148 ml Front Rack Capacity 32 kg Rear Rack Capacity 45 kg Hitch T ongue W eight Capacity 34 kg (Rea r rack capacity a nd tongue wei[...]

115 SPECIFICA TIONS Jetting Chart Clutching Chart Hawkeye 4X4 International T ires/Pressure, Front 22x7-12 / 34.5 KPa T ires/Pressure, Rear 22x10-12 / 34.5 KPa Front Suspension MacPherson strut with 18 cm travel Rear Suspension Progressive rate with 20 cm travel Shock Adjustment CAM Brake, Hand All-wheel hydraulic disc Brake, Foot All-wheel hydraul[...]

116 W ARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED W ARRANTY on all components of the Polaris Quadricycle against defects in material or workmans hip. This warranty covers the parts and labor charges for repair or replacement of defective parts which are cove red by this warranty . Th[...]

117 WA RRANTY WARRANTY COVERAGE AND EX CL USIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris limi ted warranty exclude s any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper ha ndling. This warranty also doe s not cover any Qu[...]

118 W ARRANTY LIMIT A TIONS OF WARR ANTIES AND REMEDIES ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AN D FITNESS FOR A P A R- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE TWO YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EX PRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . So[...]

119 MAINTENANCE L OG Present this section of your ma nual to your dealer each ti me you r 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[...]

120 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

121 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 101 Age Restricti ons . . . . . . . . . . . . . . . . . 6 Air Filte r . . . . . . . . . . . . . . . . . . . . . . 78 All Wheel Drive Switch . . . . . . . . . . 36 All Wheel Drive System . . . . . . . . . . 44 AWD System . . . . . . . . . . . . . . . . . . 44 B Battery Charging (Conventio[...]

122 INDEX I Idle RPM Adjustme nt . . . . . . . . . . 105 Immersion . . . . . . . . . . . . . . . . . . 85-86 Instrument Cluster . . . . . . . . . . . . 45-46 J Jetting Chart, 2X 4 . . . . . . . . . . . . . 113 Jetting Chart, 4X 4 . . . . . . . . . . . . . 115 K Key Switch. . . . . . . . . . . . . . . . . . . . 35 K-Turn . . . . . . . . . . . . . . [...]

123 INDEX T Taillight . . . . . . . . . . . . . . . . . . . . . . . 81 Throttle Cable Freeplay . . . . . . . . . 106 Throttle Leve r . . . . . . . . . . . . . . . . . . 37 Tire Tread Depth. . . . . . . . . . . . . . . . 76 Tires Front Wheel Hub Tightening . . 76 Tread Depth . . . . . . . . . . . . . . . 76 Wheel Installation . . . . . . . . . . . 7[...]