Polaris Hawkeye 300 2X4 manual

[...]

[...]

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

2 POLARIS and POLARIS THE W A Y OUT are registered t rademarks 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 pub lication. Due to constant improvements in the design and quality of production compo nents, 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 O UR VEHICLE As the operator of the vehicle, yo u are responsible for your persona l safety , the safety o f 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. Ride r esponsibly . Know [...]

5 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual 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 safe ty alert symb ol , on your vehicle or in this manual, alerts you to the potential for in ju[...]

6 SAFETY Operator Safety Safety T raining When you purchased your new Quadricycle, your dealer offered a hands-on safety traini ng course. Y ou were also provi ded 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 Polar[...]

7 SAFETY Operator Safety Read and understand all warnin gs, cautions and operating proce dures in this manual and on the safety label s before operating the Quadricycl e. Read and understand all warnin gs, cautions and operating proce dures in this manual and on the safety label s before operating the Quadricycl e. Never operate a Quadricycle wit h[...]

8 SAFETY Operator Safety Always wear an approved helmet that fits properly . W ear eye protection (goggles or face shield), glo ves, boots, long sle eves and long pants. Never consum e alcohol or dr ugs before or while operating a Quadricycle. Never operate at excessive speeds. T ravel and turn at speeds appropriate for the terrain, visibility , op[...]

9 SAFETY Operator Safety Always inspect your Quadricycle before each us e to verify that it's i n safe operating conditi on. F ollow the inspection and maintenan ce procedures outlined in this manual. See page 49. Keep both hands on the handlebars. Ke ep your feet on the footrests. Always travel slowly when ope rating on unfamiliar terrain. Us[...]

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 (b ut not limited 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 a[...]

11 SAFETY Operator Safety Always follow the procedures ou tlined in this manual for b raking if you sta ll or roll backwards while climbing a hill. Never back down a hill. See page 26. Always follow the procedures ou tlined in this manual for operating ove r obstacles. See page 21. Always follow the procedures ou tlined in this manual for operating[...]

12 SAFETY Operator Safety Always follow the procedures ou tlined 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 installa tion or us e of accessories. Never exceed the stated loa d capacity for you[...]

13 SAFETY Operator Safety Never operate the Quadricycle on a frozen body of water . Operating on paved surfaces may seriously affect the handl ing 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 i s [...]

14 SAFETY Safety Decals and Locations W arning decals have been pl aced on the vehicle fo r your protectio n. 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 sa fety decals are provided by Polaris at no charge. The part number i[...]

15 SAFETY Safety Decals and Locations “No P asseng er” W arning WARNING NEVER ride as a passenger . P assenge rs 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 ehicle Weight) 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 na da bear a U.S. Department 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 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[...]

18 SAFETY Driving Safely Driving Procedures 1. Sit upright. Keep your feet o n th e footrests. Keep both hands on the handlebars. 2. Apply the brakes. 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 brakes. 7. Slowly squeeze the thrott[...]

19 SAFETY Driving Safely T urning the V ehicle 1. Before turning, activate a turn signal to alert others of you r intentions. Activate the left signal before a left turn. Acti- vate the right signal before a right turn. 2. S teer in the direction of the turn, leaning your up per body to the inside of the turn while supporting your weight on the out[...]

20 SAFETY Driving Safely Driving on Slippery Surfaces Whenever driving on slip pery or loose surfaces suc h as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down b efore driving 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 turn[...]

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 ob stacle. 2. Be alert. W atch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. A void ha zards such as logs, rocks and low branches.[...]

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 th e footrests. 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 br ake. Se e page 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 angl e, which can caus e the vehicle to pitch sharply to one side. Drive straig[...]

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. S top the vehicle. Keep your weight uphill. 2. Lock the hydra u lic parking brake. 3. Leave the transmission in forw ard gear . T urn the engi ne of f. 4. Dismount on the uphill s[...]

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. W ith the transmission still in forward, start the engine. 12. Squeeze and release the brake le ver to release 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 current before cros sing. 2. A void operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly , balance your weight carefully an d avoid sudden movements. Mainta in a slow and steady[...]

29 SAFETY Driving Safely Driving Through W ater Always follow the procedures ou tlined in this manual for driving th rough water . Never drive through 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 wh eels on the downhil l side. 4. T urn the fuel valve off.[...]

31 SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. A void backing down- hill. 2. Always check for obstacles or pe ople 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 additio[...]

32 SAFETY Driving Safely Hauling Cargo WA R N I N G Overloading the vehi cle or carrying or towing cargo improperly can alter vehicle handling and may ca use loss of co ntrol or brake instability . Always follow these precautions wh en hauling cargo. • Read and understand the load distribut ion warnings listed on the vehicl e warning labels. • [...]

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

34 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 45 . T o gain additional power whil e 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 sw[...]

35 FEA TURES AND CONTROLS Switches Main K ey Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. S tart 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 swi[...]

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 foot rest. The foot brake operates both front and rear brakes. Press the brake pedal down with your 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 handleb ar . 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 . WA R N I N G Operati[...]

40 FEA TURES AND CONTROLS Steering Lock Lock the steering to prevent unauthor ized use or theft of the vehicle. 1. T urn the handlebars to the full left position. 2. Insert the steering lock key an d 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 m[...]

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. D o 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 ri ght front wheel well. ON: For normal oper[...]

42 FEA TURES 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 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 engin e, use the recoil starte r . Follow the starting procedures on page 50, c ranking the engine with the recoil starter instead of the main key switc h. 1. Grasp the recoil starte r rope handle tightly . 2. Pull slightly until the starter mechanism engages. 3. Pull [...]

44 FEA TURES AND CONTROLS All Wheel Drive (A WD) System (4X4 Models) The A W D switch may be turned on or of f 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 o[...]

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/Kil ometers T oggle The display in the tr[...]

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 WA R N I N G Gasoline is h ighly flammable and explosive u nder certain condition s. • Use extreme caution whenever ha ndling gasolin e. • Refuel with the engine stop ped. Ref uel outdoors or in a well -ventilated area. • Never fill a fuel container while i t's on the vehicl e. Static electricity between the ra[...]

48 OPERA TION Break-In P e riod 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 fol lowing the procedures fo r a proper break-in. Careful [...]

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 i f necessary 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 us e the chok e if st arting a warm engine. Excessive use of the choke can cause the spark plug to become we[...]

51 OPERA TION Starting the Engine 7. T urn the ignition key past the POSIT ION 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 [...]

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 requirements. Spark Arrestor Y our Polaris vehicle has a spark arrestor tha t was designed for on-road and of f-road operation. It is required that this spark arrestor re[...]

53 MAINTENANCE P eriodic Maintenance Chart Maintena nce interval s in the fo llowing ch art are ba sed upon averag e 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 Mainte nance Log begi nning on page 1 1 9[...]

54 MAINTENANCE P eriodic Maintenance 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 affect emissions.) Q Have an authorized Polaris dealer perform these services. WA R N I N G Impro[...]

55 MAINTENANCE P eriodic Maintenance 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 Calen[...]

56 MAINTENANCE P eriodic Maintenance 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) I[...]

57 MAINTENANCE P eriodic Maintenance 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) Inspec[...]

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 P olaris Premium 4 Synthetic 0W -50 See page 59. Brake Fluid DOT 4 Only See page 7[...]

59 MAINTENANCE Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Always chan ge 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 a[...]

60 MAINTENANCE Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. S tart the engine. All ow it to idle for 30 seconds. 4. S top the engine. 5. Remove th e dipstick . W ipe it dry with a clean cloth. 6. Reinstall the dipstick completely . 7. Remove th e dipstick and check the oil level. Add oil as[...]

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. All ow 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. C[...]

62 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 [...]

63 MAINTENANCE Oil and Filter Change 15. Remov e the dipstic k. 16. Add the recomme nded oil. See page 59. 17. Reinstall the dipstick. 18. S tart the engine. All ow it to idle for two minutes. 19. Stop the engine. 20. Check for oil leaks. 21. Check th e oil level. Add oil as needed. Main- tain the oil level in the safe range. Do not overfill. 22. R[...]

64 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginnin g on page 53. Use the recommended oil. Maintain the oil level at the bottom of the fill plug hole. See page 107 for the 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 recomme nded oil as nee ded. Do not overfill. 6. Reinstall the fill plug. T orque 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 under 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 speci[...]

67 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the 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 pag e 107 for the part numb ers of Polari s prod- ucts. Maintain t[...]

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 recomme nded 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 th e recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may i ndicate a fluid leak or lo w fluid level. A low flui d level may also mean that brake pads are wo rn [...]

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 edge 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 m[...]

72 MAINTENANCE Brake Fluid F oot Brake The brake fluid reservoir is located near the foot brake. Maintain the fluid level between the minimum and 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 br ake. Both b rake sy stems are self- 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 operat[...]

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 hand lebars 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 th e stands, making sure the string[...]

75 MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loo se nuts and bolts. If loose nuts and bolts are foun d, see your Polaris dea ler 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. R[...]

76 MAINTENANCE Tires Refer to the specifications section beginning on 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 operati ons. 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 wheel slightly off the ground. 5. Remove the wh eel nuts. 6. Remove the wheel. 7. Place the wheel on the hub. 8. Install t[...]

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 b eginning 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 clip s, and rem ove the air box cover [...]

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. Hol d the plastic part of the lamp. 1. Place the transmission in P ARK. 2. Open the front rack cover . 3. Remove the p[...]

81 MAINTENANCE Lights T aillight/Brakelight Lamp Replacemen t 1. From the rear of the brake- light, remove the two screws holding the lens cover in place. R emove 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 trans[...]

82 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet conditions. Dr ain the housin g 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 begi nning on page 1 12 for the recom- mended spark plug type and gap for yo ur vehicle. T orque spark plugs to specification. 1. Remove the left side panel. See page 75. 2. Remove the spa rk 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 operat ion. 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 S park Plug The normal insulator tip is t an or brown.[...]

85 MAINTENANCE V ehicle Immersion If your vehicle has been totally submerged in water and it's impossible to have it servi ced before further operation, perform the following procedure. 1. Move the vehicle out of the water . 2. T urn the fuel valve of f. 3. Remo ve the sp ark 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 specification. 10. T urn the fuel valve on. 1 1. Attempt to start the e[...]

87 MAINTENANCE Spark Arrestor Occasionally , the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Pur ge the spa rk arrestor . 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. 3. Remove the arrestor clean-out plug from t he bottom of the muf fler . 4. S tart the engine. 5. Quick[...]

88 MAINTENANCE PVT System PVT Drying If water is ingested into the PVT system, dry it before operating the vehicle. 1. Move the vehicle out of the water . 2. Place the transmission in PA R K . WA R N I N G 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 ha[...]

89 MAINTENANCE PVT System PVT Drying 3. Remove the P VT drain plug. Use a 17 mm w rench, a f lat scre w- driver , or the spa rk plug wrench. 4. Allow the water to drain com- pletely . Reinstall the drain plug. 5. S tart 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[...]

90 MAINTENANCE Battery Y our vehicle may have either a sealed battery , which requires little maintenance, or a conventional battery . A sealed 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 conne[...]

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 ba ttery vent tube. 5. Disconnect the black (nega- tive) battery ca ble first. 6. Disconnect the red (p osi- tive) battery ca ble last. 7. Lift the battery o ut of [...]

92 MAINTENANCE Battery Battery Installation 1. Ensure that the battery is fully char ged. 2. Place the batte ry in the batter y holder . 3. W ith conventional batteries, install the battery vent t ube (sealed bat- teries do not have a vent tube). NOTE: The vent tube must be free of obstr uctions and securely installed. Route the tube away fro m the[...]

93 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 r ge as needed to maintain a full charge. NOTE: Battery[...]

94 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prev ent damage from leak- ing or spilled ele ctrolyte during cha r ging. See pa ge 91. 2. Char ge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.[...]

95 MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully . 1. Check the battery voltage with a volt meter or multimeter . A fully charged batt ery 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 componen ts. High water pressure may damage components. Polaris re commends washing the vehicle by ha nd or with a garden hose, using mild soap. Certain products, including inse[...]

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

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 whee ls exposed to road salt (or salt in th e air in coastal areas) are more su sceptible to corrosion if not properly cl ea[...]

99 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. See page 96. 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 Cl[...]

100 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as reco mmended in the Pe riodic Maintenance Chart beginning on page 5 3. • 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[...]

101 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing 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 [...]

102 MAINTENANCE T ransporting 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 off. 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 ansport ing uni[...]

103 ADJUSTMENTS 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 dealer . Rear Adjuster Fr o n t Adjuster[...]

104 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 t he front two bolts to 14-17 N-m, then t[...]

105 ADJUSTMENTS Carburetor Y our Polaris Quadricycle is calibrate d at the factory for optimal perfor- mance at altitudes ran ging from zero to 1800 meters and temperatu res 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 incr ease in[...]

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 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 1.6-3.2 m[...]

107 POL ARIS PRODUCTS Pa r t N u m 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 (.95 l) 2874866 P erformance Syn thetic 4-St roke (PS-4) 0W -50 Oil (3.8 l) Gearcase / T ransmis sion Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (.95 l) 2873603 Pre[...]

108 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 26). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or u se low range[...]

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

110 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[...]

111 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 (if equipped) W ater is present in fuel Replace wi th fresh recommended fuel Old or non-recommended fuel Replac e wit[...]

112 SPECIFICA T IONS * Based on EU Directive 76/432/EC Hawkeye 2X4 International Gross V ehicle W eight 423 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 3 4 kg (Rea r rack capacity a nd tongue we[...]

113 SPECIFICA TIONS Jetting Chart Clutching Ch art 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 hydrau[...]

114 SPECIFICA T IONS * Based on EU Directive 76/432/EC Hawkeye 4X4 International Gross V ehicle W eight 423 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 Ch art 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 hydrau[...]

116 W ARRANTY LIMITED W ARRANTY 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 workma nship. This warranty covers the parts and labor char ges for repair or replacement of defe ctive parts whic h are cove red by this warranty [...]

117 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 ha ndling. This warranty also doe s not cover any Q[...]

118 W ARRANTY LIMIT A TIONS OF W ARR ANTIES AND RE MEDIES ALL IMPLIED W ARRANTIES (INCLUDING BUT N OT LIMITED TO THE IMPLIED W ARRANTIES O F MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE TWO YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . S[...]

119 MAINTENANCE L OG Present this section of your ma nual 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[...]

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

121 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 101 Age Restric tions . . . . . . . . . . . . . . . . . 6 Air Filt er . . . . . . . . . . . . . . . . . . . . . . 78 All Wheel D rive Switch . . . . . . . . . . 36 All Wheel D rive Syste m . . . . . . . . . . 44 AWD Sys tem . . . . . . . . . . . . . . . . . . 44 B Battery Charging (Conve[...]

122 INDEX I Idle RPM Adju stment . . . . . . . . . . 105 Immersion . . . . . . . . . . . . . . . . . . 85-86 Instrument Cluster . . . . . . . . . . . . 45-46 J Jetting Chart , 2X4 . . . . . . . . . . . . . 113 Jetting Chart , 4X4 . . . . . . . . . . . . . 115 K Key Switch. . . . . . . . . . . . . . . . . . . . 35 K-Turn . . . . . . . . . . . . . . [...]

123 INDEX T Taillight . . . . . . . . . . . . . . . . . . . . . . . 81 Throttle Cable Fre eplay . . . . . . . . . 106 Throttle Lever . . . . . . . . . . . . . . . . . . 37 Tire Trea d Depth . . . . . . . . . . . . . . . . 76 Tires Front Wheel Hub Tightening . . 76 Tread Depth . . . . . . . . . . . . . . . 76 Wheel Installat ion . . . . . . . . . . [...]