Polaris 300 4X4 manual

[...]

05[...]

A card containing impo rtant A TV safety informatio n should be attached to the owner's manua l on the next page. If you cannot locate this card, or if it has been removed, p lease call 1 -800-342- 3764 for assistan ce. W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductive [...]

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 excit ing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excellence for a ll [...]

2 POLARIS and POLARIS TH E W A Y OUT are registered tradem arks of Polaris Indus - tries Inc. Copyright 2006 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discrep[...]

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

4[...]

5 KNOW Y OUR VEHICLE As the operator of the vehicle, y o u are responsible for your personal safety , the safety of others, and th e protection of our environment. Read and understand your owner's manu al, which includes valuable informa- tion about all aspe cts of your vehicle, incl uding safe operati ng proce- dures. V ehicle Identification [...]

6 SAFETY Safety Decals and Locations W arning decals have been placed on t he A TV for your p rotection. Read and follow the instructions of the de cals on the A TV carefully . If any of the decals depicted in this manual dif fer f rom the decals on your A TV , always read and follow the instruc tions of the decals on the A TV . If any decal become[...]

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

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

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

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

11 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof 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 [...]

12 SAFETY Operator Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. WAR N I N G F ailure to follow the warnings contained in this manual can result in severe injury or death. A Polaris A TV is not a toy a nd can be hazardous to operate. This vehicle h an- dles differently t[...]

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

14 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 meanings before reading the manual. The safety ale rt symbol , on your vehicle or in thi s manual, alerts you to the potential for injury .[...]

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

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

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

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

19 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Operating this A TV without proper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if th e operator does not know how to operate the A TV properly in different situ ations and on differ ent types of terrain. HOW TO A VOID THE HAZARD Beginning and inexperienced operato[...]

20 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Carrying a passe nger on an A TV . WHA T CAN HAPPEN Carrying a passenger greatly reduces the oper- ator's ability to balance and control the A TV , which could cause an accident and injury to the operator and/or passenger . HOW TO A VOID THE HAZARD Never carry a passenger . The pu rpose of[...]

21 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Operating this A TV on p ublic streets, roads or highways. WHA T CAN HAPPEN The A TV could collide with another vehicle. HOW TO A VOID THE HAZARD Never operate the A TV on any public street, road or highway , including dirt and gra vel roads. In many states it's illegal to operate A TVs on[...]

22 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Operating the A TV after consuming alcohol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drugs cou ld seri- ously affect operator judgment. Reactio n time may be slower and operator balance and per- ception could be affected. Consuming alcohol and/or drugs before or whi le operating [...]

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

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

25 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD F ailure to use extra caution when operating on excessive ly rough, slip- pery or loose terrain. WHA T CAN HAPPEN Operating on exce ssively rough, slip- pery or loose terrain could cause loss of traction or loss of co ntrol, which could result in an accident or over- turn. HOW TO A VOID THE HAZ[...]

26 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Operating on exce ssively steep hills. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZARD Never operate on hills too steep for the A TV or for your abilities. Never o perate the A TV on hill s steeper than 25 degrees. WAR N I N G POTENTIAL HAZARD Climbing hills improperly . WHA[...]

27 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD T raveling downhil l improperly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A specia l technique is required when braking[...]

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

29 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Improperly operating over obstacles. WHA T CAN HAPPEN Operatin g over obstacle s could cause lo ss of control or over turn. HOW TO A VOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoid[...]

30 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Operating the A TV through deep or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or o verturn. HOW TO A VOID THE HAZARD Avoid operating the A TV through deep or fast-flowing water . If it's unavoidable t[...]

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

32 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Overloading the A TV or carrying/towing cargo improperly . WHA T CAN HAPPEN Overloading and towing can cause change s in vehicle handling, wh ich could lead to loss of control or an accident. HOW TO A VOID THE HAZARD Never exceed the stated load capacity for this A TV . Cargo should be p roperl[...]

33 SAFETY Operator Safety WAR N I N G Operating a dama ged A TV can result i n an accident w ith serious inj ury or death. After any o verturn or accid ent, have a qua lified service dealer inspect the entire machine for possible damage, incl uding (but not limited to) brakes, throttle and st eering systems. WAR N I N G Safe operation of this rider[...]

34 FEA T URES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limi ter system.T o gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of All Whe el Drive in reverse, if the AWD switch is on. This switch is also used to toggle through the[...]

35 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch ei ther left or right to the OFF position to stop the engi ne quickly . Th e engine will no t start or run whe n the switch is of f. NOTE: Both the main sw itch and the engine stop switch will shut off all electri- cal power to the vehi cle, includ ing light s. Main Key Swit[...]

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

37 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 brakes that are ac tivated by only one lever . Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any spongin[...]

38 FEA T URES AND CONTROLS Pa r k i n g B r a k e Locking the P arking Brake 1. Place the transmission in gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lock, squeeze and relea se the bra[...]

39 FEA TURES AND CONTROLS Auxiliary F oot Brake The auxili ary brake syst em is intend ed to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. The auxili ary foot brak e is located on the inside of the right footrest. Operate this brake with your right foot. NOTE: If the rear wheels slide whil[...]

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

41 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 Whenever the A TV is left unattended, always place the transmission in gear and lock the parking brake. CA UTION Shifting gears with the engin e speed above idle or while the[...]

42 FEA T URES 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 slowly so you can feel the engine strokes. NOTE: The rop[...]

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

44 FEA T URES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the A TV's speed to approximately 7-9 mph. Refer to [...]

45 FEA 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[...]

46 OPERA T ION F uel Safety WAR N I N G Gasoline is h ighly flammable and e xplosive under certain con ditions. • Always exercise extreme caution w henever handling gasoli ne. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is[...]

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

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

49 OPERA TION Pre-Ride Checklist WAR N I N G If a proper inspection is not done befor e ea ch use, severe i njury or death could result. Always inspect the vehicl e before each use to ensure it's in proper operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 37 86 Brake fluid Ensure proper level 84 Auxiliar[...]

50 OPERA T ION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. NOTE: The starter in terlock will prevent the engine from starting if the trans- mission is in gear and the brake is not enga ged. 4. T urn the fuel valve on. 5. Sit on the vehicle. NOTE: Do not use the cho[...]

51 OPERA TION Starting the Engine 8. T urn the ignition key past the ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the en gine starts. 9. If the engine does not start, return the key to the OFF position an d wait five seconds before attemptin g to start again. Activate the starter for[...]

52 OPERA T ION Hauling Cargo Y our A TV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifi- cations section of the owner's manual and on the safety decals. Carg o weight should b e evenly distr[...]

53 OPERA TION Hauling Cargo WAR N I N G Hauling cargo imprope rly can alter vehicle handling and may cause loss of control or brake instability and result in serious inju ry or death. Always follow these precautions when haul ing cargo: REDUCE SPEED AND ALL OW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO . CARGO WEIGHT DISTRIBUTI ON should be[...]

54 OPERA T ION Driving Safely Driving Procedures 1. W ear protective riding gear . See page 10. 2. Sit upright with both feet on th e footrests and both hands on the handlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check your surroun dings and determine your path of travel. 6. Release the parking br[...]

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

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

57 OPERA TION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Keep both feet on the footrests. 4. Shift your weight uphill. 5. Proceed at a ste ady rate of speed and t hrottle opening. 6. Remain al ert and be prepa red to take emer gency action. T[...]

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

59 OPERA TION Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Shift your weight uphill. 2. Drive straight downhill. 3. Slow down. 4. Squeeze the brake lever gradually . NOTE: Before operating yo ur A TV , learn how to use the au xiliary brake fo r emergency situations (if singl e-lever brakes become inoperab le).[...]

60 OPERA T ION Driving Safely T urning Around on a Hill (K - T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m)[...]

61 OPERA TION Driving Safely T urning Around on a Hill (K - T urn) 1. S top and lock the parking brake while keeping body weight up hill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hicle, or on the left if the vehi- cle is pointin g straight uphill. 4. Staying uphill of the vehicle, turn t[...]

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

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

64 OPERA T ION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and lo w hanging branches. WAR N I N G Severe injury or death can result if your vehicle comes in contact with a hid- den obstacle. Not all obstacles are immediately vi[...]

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

66 OPERA T ION Driving Safely P arking on an Incline A void parking on an incline if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Always block the rear wheels on th e downhill side. 5. T urn the fuel valve off.[...]

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

68 MAINTENANCE P eriodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main tenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the ne[...]

69 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. WAR N I N G Improp[...]

70 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[...]

71 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[...]

72 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[...]

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

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

75 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the A TV . 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Star t the engine. Allow it to idle for 30 seconds. Stop the engi ne. 5. Remove the dip stick. W ipe it dry with a clean clo[...]

76 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 68. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Star t the engine. Allow it to id[...]

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

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

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

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

81 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart begi nning on page 68. W e recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of compo - nents. See page 119 for the part number[...]

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

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

84 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. If the fluid level is low add DOT 4 brake fluid only . See page 1 19 for the part numbers of Po laris products. Under normal operation, the diaphr agm extends into the reservoir as fluid[...]

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

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

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

88 MAINTENANCE Steering Assembly The steering assembly o f the A TV should be checked periodically for loose nuts and bolts. If loose nu ts and bolts are found, see your Polaris dealer for service before operati ng 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 Rem[...]

89 MAINTENANCE Tires Refer to the specifications section begin n ing on page 124 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. F ront Wheel Hub Tightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operations. All se[...]

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

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

92 MAINTENANCE Air Filter/Breather Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Remove the seat. 5. Release the air box cover clips, and remove the air box cover . 6. Remove the air filter . 7. Remove the sleeve from the filter . 8. W as h the sleeve in soapy water, then rinse [...]

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

94 MAINTENANCE Lights When servicing a halo gen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlamp Replacement 1. T urn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly . 2. Remove[...]

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

96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications sect ion beginning on page 124 for the recom- mended spark plug t ype and gap for your vehicle. T orque spark plugs to specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operation. Check the spark plug firing end condition after the en [...]

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

98 MAINTENANCE V ehicle Immersion If it's impossible to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the vehicle out o f the water . 2. T urn the fuel valve off. 3. Check the air box. If water is present, dry the air box and replace the filter with a new filter . 4. Remove the sp ark plug. 5. Loosen [...]

99 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur ge acc umulated carbon from the exhaus t pipe/muffler . 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Remove the arrestor clean-out plu g from the bottom of the muffl e r . 5. Star t the engine. 6. Quickly[...]

100 MAINTENANCE PVT System WAR N I N G F ailure to comply with the instru ctions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failu re may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be [...]

101 MAINTENANCE PVT System PVT Drying There ma y be some in stances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Move the vehicle out o f the water . 2. Remove the PVT drain p lug. Use a 17 mm wre nch, a flat screw- driver , or the spa rk plug wrench. 3. Allow the water to [...]

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

103 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parking brake. 3. Open the front cover . 4. Disconnect the battery hold- down strap. 5. On conventional batteries, remove the batte ry vent tube. 6. Disconnect the black (nega- tive) battery cable first. 7. Disconnect the red (posi- tive) battery cable las t. 8.[...]

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

105 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 ge d, 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[...]

106 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to p revent damage from leak- ing or spilled electrolyt e during charging. See page 103. 2. Charge 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 1.27[...]

107 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery con dition before and 1-2 hours after the end of charging. State of Charge V oltage Action Charge Time (Using constant cur rent charger @ standard amps specifie d on top of batter y) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required[...]

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

109 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 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 •[...]

110 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susce ptible to corrosion if no t properly clean[...]

111 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Se e page 108. 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 ommended amount. NOTE: Carbon C[...]

112 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 68. • 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[...]

113 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 68. Battery Storage See pages 105-106 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV with th[...]

114 MAINTENANCE T r ansporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. T urn the fuel valve off. 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 A TV to t[...]

115 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Spring Adjustments The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrea se spring tension. Always ad just both sides equally . NOTE: Accessory springs are available throug h your Polaris dea[...]

116 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. 1. Loosen the four ha ndlebar 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 10-12 ft. lbs. (14-[...]

117 ADJUSTMENTS Carburetor Y our Polaris A TV is calibrated at the factor y for optimal performa nce at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) or higher . Above 6000 feet (1 800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea [...]

118 ADJUSTMENTS Throttle Cable F reeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and 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 1/16&quo[...]

119 POL ARIS PRODUCTS Pa rt N u m b er Description Engine Lubri cant 2870791 Fogging Oil (12 oz. Aerosol) 2874865 Performance Synthetic 4-St roke (PS-4) 0W -50 Oil (qt.) 2874866 Performance Synthetic 4-Stroke (PS-4) 0W-50 Oil (gal.) Gearcase / T ransmis sion Lubricants 2873602 Premium AGL Synthetic Gear case Lubricant (qt.) 2873603 Premium AGL Synt[...]

120 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 60). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range (if[...]

121 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to Start Engine Backfires Possible Cause Solution Blown fuse Replace fuse 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 Solutio[...]

122 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 [...]

123 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 W ater is present in fuel Replace with new fuel Overuse of choke Ins pect, clea n a nd/or replace spark plugs Fouled o[...]

124 SPECIFICA TIONS * Based on EU Directive 76/432/EC Hawkeye 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) Demand Drive Flui d 5 oz. (148 ml) Front Rack Capacity 70 lbs. (32 kg ) Rear Rack Capacity 100 lbs. (45 kg) Hit[...]

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

126 SPECIFICA TIONS * Based on EU Directive 76/432/EC Hawkeye 4X4 Gross V ehicle W eight 930 lbs. (422 kg) Dry W 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[...]

127 SPECIFICA TIONS Jetting Chart Clutching Chart Hawkeye 4X4 Drive Ratio, Front 3.6:1 Drive Ratio, Final 15.18:1 T ires/Pressure, Standard 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 7&qu[...]

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

129 WA RRANTY WARRANTY COVERAGE AND EX CLUSIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIE S 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 handling. This warranty also does not cover any A TV[...]

130 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A T ED IN THIS W ARR ANTY . Some states do not allow lim i- tations on ho[...]

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

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

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

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

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

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

136 INDEX A Accessories . . . . . . . . . . . . . . . . . . 113 Age Restrictions. . . . . . . . . . . . . . . . 12 Air Filte r . . . . . . . . . . . . . . . . . . . . . 92 All Wheel Drive Switch. . . . . . . . . . 35 All Wheel Drive System . . . . . . . . . 43 AWD Switch . . . . . . . . . . . . . . . . . . 43 AWD System . . . . . . . . . . . . . . [...]

138 INDEX T Taillight . . . . . . . . . . . . . . . . . . . . . . 94 Throttle Cable Freeplay . . . . . . . . . 118 Throttle Lever . . . . . . . . . . . . . . . . . 36 Tire Tread Depth . . . . . . . . . . . . . . . 89 Tires Front Wheel Hub Tightening . . 89 Tread Depth . . . . . . . . . . . . . . . 89 Wheel Installation . . . . . . . . . . 91 Wheel [...]