Polaris Hawkeye 922362 manual

Owner's Manual for Maintenance and Safety Read this manual carefully . It contains important safety information. This is an adult vehicle only . Operation is prohibited for those under 16 years of age. P antone 426 C HA WKEYE 2X4[...]

The text is printed on 100% recycled with 40% post-consume r waste (PCW).[...]

P antone 426 C For your nearest Polaris dealer , visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 U.S.A. Part No. 9922362 Rev 0 2 Printed in U.S.A. W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without pr oper training or instruction. S at speeds too fast for your skills [...]

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

2 POLARIS, THE W A Y OUT and HA WKEYE are register ed trademarks of Polaris Industries Inc. Copyright 2009 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 compo nents, some minor discrep-[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Emission Control Systems . . . . . . . . . . . . [...]

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5 INTRODUCTION 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 meanings before reading t he manual. The safety ale rt symbol indicates a potential persona l injury hazard. W ARNING A W ARNING indicates a hazardous[...]

6 INTRODUCTION Failure to follow the warni ngs in this manual can result in se rious injury or death. This Polaris vehi cle is not a toy and can be hazardous to operate. A collision or rollover can occur q uickly , even during routine man euvers, if you fail to take proper precaution s. Read and understand your owner's manu al and all warni ng[...]

7 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key nu mber in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using yo ur key number) and matin g it with one of yo ur existing keys. The ignition swit[...]

8 SAFETY Operator Safety Serious injury or death can result if you do not follow the instruction s and procedures listed here a nd throughout this manual . Read and understand all warnings, cautio ns and operating p rocedures in thi s manual and on the safety labels before operating this vehicle. Never operate this vehicle without proper instructio[...]

9 SAFETY Operator Safety Always wear an approved helmet that fits properly . Wear eye protection (goggles o r face shield), gloves, boots, long sleeves and long pants. Never consume alcoho l or drugs before or while operating this vehicle . Never operate at excessive speeds. T ravel and turn at speeds appropriate fo r the terrain, visi bility , ope[...]

10 SAFETY Operator Safety Always inspect your vehicle before each use to verify th at it's in safe operating condition. Fol low the inspection and maintenance procedures outlined in this manual. See page 35. Keep both h ands on the ha ndlebars. Keep both feet on the footrests. Always travel slowly when ope rating on unfamiliar terra in. Use ex[...]

11 SAFETY Operator Safety Always follow the procedures ou tlined in thi s manual for turning. Never tu rn sharply at excessive speeds, which ca n lead to vehicle overturn. See pa ge 39. If this vehicle has been involved i n an accident, always have an authorized Pola ris dealer inspect the entire vehicle for possible damage, including (but not limi[...]

12 SAFETY Operator Safety Always follow the procedures ou tlined in this manual for braking if you stall or roll backwards while climbing a hi ll. Never back down a hill. See page 44. Always follow the procedures outl ined in this manual for operating over obstacles. See p age 48. Always follow the pro cedures outlined in thi s manual for operating[...]

13 SAFETY Operator Safety Never modify this vehicle through improper installation or use o f accessories. Never exceed the stated load cap acity fo r your vehicle. Cargo must b e properly distributed and securely attached. Reduce spee d and follow the instructi ons in this manual for carrying cargo or towing. Allow a grea ter distance for braking. [...]

14 SAFETY Safety Labels and Locations W arning labe ls have been placed on the ve hicle for your protection . Read and follow the instructions on each label carefully . If a label becomes illegible or comes of f, contact your Polaris dealer to purchase a replacement. Replacement safety labe ls are provided by Polaris at no charge. The part number i[...]

15 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate thi s A TV on HILLS steeper than 25 degrees 25 ° . T o prevent overturn on hilly ter- rain, use throttle and brakes grad- ually , and shift weight uphill. • REVERSE operatio n can be dan- gerous even at low speeds. S teer- ing becomes difficult. T o prevent l[...]

16 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a p assenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 Age 16 W arning W ARNING Operating this A TV if you a re under the age of 16 increases your chance of severe injury or d eath. NEVER operate this A TV if you [...]

17 SAFETY Safety Labels and Locations Clutch Cover W arning W ARNING NO STEP • Moving part s hazard und er belt-clutch gu ard. T o pr event serious injury , do no t operate vehicle with guard 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 [...]

18 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[...]

19 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 Equ i pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make [...]

20 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse spee d limiter system .T o gain additional power while backing, depress the override switch. The overrid e switch al so allows activation of All Wheel Drive in reverse, if the A WD switch is on. Th is switch is also used to toggle through the m[...]

21 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the e ngine quickly . The engine will not start or ru n when the switch is of f. Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights. Main K ey Switch Use the m[...]

22 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever . The throttle lever is spring loaded. Engine speed re turns to idle when the lever is released. Failure to check or ma intain proper operation o f the throttle system can resul t in an accident if the thrott le lever sticks duri[...]

23 FEA TURES 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 are activated by only one lever . Always test brake lever travel and master cylinder fluid level befo re riding. When squeezed, the lever should feel firm. Any spongi[...]

24 FEA TURES AND CONTROLS Parking Brake Operating this vehicle while th e parkin g brake is engag ed could re sult in an accident and serious injury or de ath. Always check to be sure th e p arking brak e is disengaged before operating. Locking the P arking Brake 1. Place the transmission in gear . 2. Squeeze and release the brake lever two or thre[...]

25 FEA TURES AND CONTROLS Auxiliary Foot Brake The auxili ary brake s ystem is in tend ed to be used as a backup for the main brake system. Should the main system fail, use the auxilia ry foot brake. Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , which could re sult in serious injury or death. Use cauti[...]

26 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 36 for correct ch oke and throttle settings during start- ing. Fuel T ank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octan[...]

27 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 Whenever this vehicle is left unattended, always place the transmission in gear and lock the parking brake. Shifting gears with the engine speed above idl e or while the vehi[...]

28 FEA TURES AND CONTROLS Recoil St arter If the battery is too weak to start the engin e, use the recoil starte r . Follow the starting procedures on page 36, cranking the 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. Tip : The ro[...]

29 FEA TURES AND CONTROLS All Wheel Drive (A WD) System (4X4 Models) The Al l Wheel Drive s ystem is controlled by the A WD switch. When the switch is on 2X4, the vehicle is in two-whee l drive at all times. When the switch is on A WD, the vehicle is in all wheel drive and the A WD indicator light in the instrument cluster will be on. When in A WD,[...]

30 FEA TURES AND CONTROLS Instrument Cluster Y our vehicle 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 this vehicle's speed to approximately 7-9 mph. Re[...]

31 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[...]

32 OPERA TION Fuel Safety Gasoline is highly flammable and explosive u nder certain conditions. • Use extreme caution whenever ha ndling gasoline. • Refuel with the engine stop ped. Refuel outdoors or in a well-ventilated area. • Never fill a fuel container while it's on the vehicle. S t atic electric ity between the rack and container c[...]

33 OPERA TION Break-In Period The break-in p eriod for your new Polaris vehicle is the first ten h ours of operation, or the time it takes to use the first two full ta nks of gaso line. 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 resu[...]

34 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. 2. Check the oil level on the dipstick. See page 61. 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 oper[...]

35 OPERA TION Pre-Ride Checklist If a proper inspection is not done before ea ch use, seve re injury or death could result. Always inspect the ve hicle before each use to ensure it' s in proper operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 23 72 Brake fluid Ensure proper level 70 Auxiliary brake Ensu[...]

36 OPERA TION S t arting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock th e parking br ake. Tip : The starter interlock will preven[...]

37 OPERA TION S t arting the Engine 8. T u rn the ignition key past the ON position to engage the 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 k ey to the OFF position and wait five seconds before attemptin g to start again. Activate the starter[...]

38 OPERA TION Driving Procedures 1. W ear protectiv e riding gear . See page 18. 2. Perform the pre-ride inspection. See page 35. 3. Sit upright with both feet on th e foo trests and both hands on the handlebars. 4. S tart the engine and allow it to warm up. 5. Shift the transmission into gear . 6. Check you r surroundings and determine your path o[...]

39 OPERA TION T urning the V ehicle Y our vehicle 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 . 1. Slow down. 2. S teer in the direction o[...]

40 OPERA TION 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. Do not operate on exces- sively rough, slippery or loose terrain. 2. Slow down wh en enter- ing slippery areas. 3. Engage A WD (if equipped) before wheels begin to lose tract[...]

41 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Whenever traveling uphill, fol low these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Always check the terra[...]

42 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proced ure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidabl e , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. [...]

43 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Before operating your vehicle, le arn how to use the auxiliary brake for emergency situations (if single -lever brakes become inoperable). 2. Always check the terrain carefully before descending a hill. 3. Shift your weight uphill. 4. Drive straight downhill. 5. Slow[...]

44 OPERA TION 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)[...]

45 OPERA TION T urning Around on a Hill (K-T urn) 1. S top and lock the parking brake while keeping bod y 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 uphi ll. 4. S taying up hill of the vehicle, turn the handlebars[...]

46 OPERA TION Driving Through W ater Y our vehicle can operate through water 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. A v oid operating through d[...]

47 OPERA TION Driving Through W ater If it’ s unavoidable to enter water deeper than the footr est level: • Proceed slowly . A void rocks and obsta cles. • Balance your weight carefully . A void sudden movements. • Maintain a steady rate of speed. Do not make sudden turns or stops . Do not make sudden throttle changes. If your vehicle becom[...]

48 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra cau tion when operating on unfamiliar[...]

49 OPERA TION 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 . 7. Do not use the override switch un[...]

50 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to wing ca rgo improperly can alter vehicl e handling and may cause loss of control or brake instability . Always follow the se precautions when hauli ng cargo. • Read and understand the load distribut ion warnings listed on the vehicle warning labels. • Never exceed the state[...]

51 OPERA TION Hauling Cargo Y our vehicle has bee n designed to ca rry or tow a certain amount of load. Always read and understand the load distri bution 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 labels. Car go weight shou ld be evenly [...]

52 OPERA TION Parking 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 br ake. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve of f.[...]

53 EMISSION 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. S p ark Arrestor Y our Polaris vehicle has a spa rk arrestor that was designed for on-road and of f-road operation. It is required that this spark arrestor r[...]

54 MAINTENANCE Periodic Maintenance Chart Maintena nce intervals in the followin g chart are based upon average riding conditions. V e hicles subjected to severe use mu st be inspected and serviced more frequently . Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the need for repl acement parts , use genui[...]

55 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedure s marked with a  could re sult in component failure and cause an accid ent, wh ich may resu lt in serious injury or death. Always have an authorize d Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subje[...]

56 MAINTENANCE Periodic 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 Calend[...]

57 MAINTENANCE Periodic 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) In[...]

58 MAINTENANCE Periodic 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) Inspect[...]

59 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintena nce Chart beginning on page 54. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS P erformance Synthetic 2W -50 See page 60. Brake Fluid DOT 4 Only See p[...]

60 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changi ng oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's [...]

61 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the vehicle. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock th e parking br ake. 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 [...]

62 MAINTENANCE Oil and Filter Change Hot oil may result in serious burns. Do not all ow hot oil to contact skin. Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 54. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level surface. 2. Place the transmissio[...]

63 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 [...]

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 54. Maintain the oil level at the bottom of the fill plug hole. See page 105 for the part numbers of Polaris products. The fill plug is located on the left side of the vehicle, under the rear f[...]

65 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 br ake. 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 64 for reco m- mendations.[...]

66 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 br ake. 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[...]

67 MAINTENANCE Front Gearcase (Dem and Drive) Fluid (if equipped) Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginning on page 54. W e recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper opera tion of compo- nents. See page 105 fo r t[...]

68 MAINTENANCE Front Gearcase (Dem and Drive) Fluid (if equipped) Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking br ake. 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 [...]

69 MAINTENANCE Front Gearcase (Dem and Drive) Fluid (if equipped) Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking br ake. 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 dr[...]

70 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride . Always maintain brake fluid at th e recommended lev el. Do not overfil l. The brakes should feel firm when they're applied. Spongy or weak brakes may i ndicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are wo rn [...]

71 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[...]

72 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[...]

73 MAINTENANCE T oe Alignment Do not attempt to adjust ti e rod alignment. All tie rod adjustments should be performed by an authorized Polaris deal er . Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Place the handlebars in a st[...]

74 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. S pring Adjustment s 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 . Tip : Accessory springs are availabl e through your Polaris de[...]

75 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. Improper adjustment of th e handlebars or incorre ct torquing of the adjuster block tig htening bolts can cause li mited steering or l oosenin g of the ha ndlebars, resulting in loss of control and possible serio us personal injury or death. Fo llow the adjustment proce [...]

76 MAINTENANCE Carburetor This vehicle is calibrated at the fa ctory for optimal performance at alti- tudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) or hig her . Above 6000 fee t (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea ch 10[...]

77 MAINTENANCE Throttle Cable Freeplay 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" [...]

78 MAINTENANCE S teering Assembly The steering as sembly of this vehicle shou ld be checked pe riodically for loose nuts and bo lts. If loose nuts and bolts are foun d, see your Polaris dealer for service before ope rating the v ehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the top of the side panel and pull it outward to remove it. Footw[...]

79 MAINTENANCE Ti r e s Operating your veh icle with worn tires, improperl y inflated ti res, non-standard tires or impro perly installed tires will affect vehicle h andling and could cause an accident resulting in serious injury or death. • Maintain proper tire pressure as described on the lab el on your vehicle and in the owner's ma nual. [...]

80 MAINTENANCE Ti r e s Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking br ake. 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.[...]

81 MAINTENANCE Ti r e s Wheel Inst allation Improperly installed wheels can adversely affect tire wear and vehicle handling, which can resu lt in serious inj ury or death. Alw ays ensure that all nuts are torqued to specification . Do not service axle nuts that have a cotter pin installed. See your Polaris dealer . 1. Place the wheel on the wheel h[...]

82 MAINTENANCE Air Filter/Breather Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock th e parking br ake. 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 , the n [...]

83 MAINTENANCE Light s 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 br ake. 4. Measure [...]

84 MAINTENANCE Light s Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. W ash the headlights and taillights frequently . Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlamp Replacement When servicing a ha logen lamp, don't touch[...]

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

86 MAINTENANCE Spa r k P l u g s S p ark Plug Recommendations Using non-recommended spark plugs can result in serious engin e damage. Always use Polaris-recommended spark plugs. Refer to the specifications section begi nning on page 1 10 for the recom- mended spark plug type and gap for your v ehicle. T orque spark plugs to specification. S p ark P[...]

87 MAINTENANCE Spa r k P l u g s S p ark 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 orque to specification. S p ark Plug Condition Normal Spar k Plug The normal insulator tip[...]

88 MAINTENANCE V ehicle Immersion If your vehicle becomes immersed, ma jor engine dama ge can result if the machine is not thoroughl y inspected. T a ke the vehicle to your dealer before st arting the en gine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below . 1. Move the vehicle out of th[...]

89 MAINTENANCE S p ark Arrestor Failure to heed the following warni ngs while servicing the spark arrestor could result in serious injury or death. The exhaust system c an get extremely hot. Do not perform service on the sp ark arrestor while the system is hot. Allow compo nents to cool suf ficiently before proceeding. Remove any combusti ble mater[...]

90 MAINTENANCE P VT System Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure ma y occur at a high speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of balance, creating vibrati on and addi tional loads on components. The PVT system rotates at high spe[...]

91 MAINTENANCE P VT System P VT Drying There m ay be some instanc es 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 PVT drain plug. Use a 17 mm wrench, a flat screwdriver , or the spark plug wrench . 3. Allow the water to dra[...]

92 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an e xplosion and cause serious injury or death. When removing the battery , alw ays disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains su[...]

93 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock th e parking br ake. 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.[...]

94 MAINTENANCE Battery Battery Inst allation 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 instructions on page 96 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the batte ry in t[...]

95 MAINTENANCE Battery Batter y St orage 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 ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during st orage and recharge as needed to maintain a full charge. Battery char g[...]

96 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled ele ctrolyte during charging. See page 9 3. 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 1.27[...]

97 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re 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 of ba ttery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-10[...]

98 MAINTENANCE Cleaning and S torage 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 components. 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 ins[...]

99 MAINTENANCE Cleaning and S torage W ash ing the 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 an d labels. 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[...]

100 MAINTENANCE Cleaning and S torage 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. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. C l[...]

101 MAINTENANCE Cleaning and S torage Sto r a g e Tips S tarting the engin e during the storage period will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended. See page 98. Stabilize the F uel 1[...]

102 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as recomm ended in the Period ic Maintenance Chart beginning on page 54. • Demand drive unit (front gearcase) (if equipped) • T ra nsmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) F og [...]

103 MAINTENANCE Cleaning and S torage Sto r a g e 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 54. Battery Storage See pages 95-96 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely su pport the veh[...]

104 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 br ake. 4. T urn the fuel valve of f. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to preven t loss during transporting. 7. Always tie the frame of the vehicle[...]

105 POLARIS PRODUCTS Pa r t Number De scription Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synt hetic 2W -50 4-Cycle Oil (gal.) Gearcase / T ransmis sion Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium AGL Syn[...]

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

107 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art 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 Solut[...]

108 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommende d 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 Soluti[...]

109 TROUBLESHOOTING Engine S top s 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 W ater is present in fuel Replace wi th new fuel Overuse of choke Ins pect, cl ean a nd/or replace spark plugs Foule[...]

110 SPECIFICA TIONS * Based on EU Directive 76/432/EC HA WKEYE 2X4 Gross V ehicle W eight 930 lbs. (422 kg) Dry W e ight 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) Front Rack Capacity 70 lbs. (32 kg) Rear Rack Capacity 100 lbs. (45 kg) Hitch T ongue W eight Capacity 7 5 lbs[...]

111 SPECIFICA TIONS Jetting Chart Clutching Ch art HA WKEYE 2X4 T ires/Pressure, Front 22x7-12 / 5 psi (34.5 KPa) T ires/Pressure, Rear 2 2x10-12 / 5 psi (34.5 KPa) 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 D[...]

112 SPECIFICA TIONS * Based on EU Directive 76/432/EC HA WKEYE 4X4 Gross V ehicle W eight 930 lbs. (422 kg) Dry W e ight 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) Hit[...]

113 SPECIFICA TIONS Jetting Chart Clutching Ch art HA WKEYE 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 ont 23x7-12 / 5 psi (34.5 KPa) Rear 23x10-12 / 5 psi (34.5 KPa) Front Suspension MacPherson strut with [...]

114 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T ele phone 763-542-0500 W e, Polaris Industries Inc., dec lare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN DIRECTIVES TEST [...]

115 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 th e Polaris vehicle against defects in material or workma nshi p. This warranty covers the parts and labor char ges for repair or replacement of defective parts which are cove r ed by this warranty . T[...]

116 W A RRANTY LIMIT A T IONS OF W ARRANTIES AND REMEDIE S Warranty does not apply to pa rts exposed to friction surfaces, stresses, environmental conditions and/or contaminati on, for which they were not designed or not intended, including but not limited to the following ite ms: W arranty applies to the product only and does not allow for coverag[...]

117 W ARRANTY LIMIT A T IONS OF W ARRANTIES AND REMEDIE S This warranty does not cover the use of unauthor ized lubrican ts, chemicals, or fuels that are not compa tible with the vehicle . The ex clusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or r eplacement of any defective materials, or components o[...]

118 MAINTENANCE LOG 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 perfor med. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMM ENTS[...]

119 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMM ENTS[...]

120 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMM ENTS[...]

121 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 103 Age Restric tions . . . . . . . . . . . . . . . . . 6 Air Filt er . . . . . . . . . . . . . . . . . . . . . . 82 All Wheel D rive Switch . . . . . . . . . . 21 All Wheel D rive System . . . . . . . . . . 29 AWD Sw itch . . . . . . . . . . . . . . . . . . . 29 AWD Sys tem . . . . . . [...]

122 INDEX H Handlebar A djustment . . . . . . . . . . . 75 Hauling Cargo . . . . . . . . . . . . . . . 50-51 Headlamp Repl acement . . . . . . . . . . 84 Headlight Beam Adjust ment . . . . . . 83 Headlight S witch . . . . . . . . . . . . . . . 21 Helmet . . . . . . . . . . . . . . . . . . . . . . . 18 I Idle RPM Adjus tment . . . . . . . . . . . 76[...]

123 INDEX S Switches AWD Switch . . . . . . . . . . . . 21, 29 Engine Stop Switch . . . . . . . . . . 21 Headlight Swit ch. . . . . . . . . . . . 21 Main Key Swi tch . . . . . . . . . . . 21 Mode/Reverse Ove rride Switch 20 T Taillight . . . . . . . . . . . . . . . . . . . . . . . 84 Throttle Cable Freepla y . . . . . . . . . . 77 Throttle Lever . [...]