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Polaris 850 Touring EPS Offroad Vehicle User Manual

1. 120 A Accessories 2 6 2 0 000 000 103 Age Restrictions 6 Air Filter 00000 82 All Wheel Drive Switch 21 All Wheel Drive Svstem 29 AWD Switch 004 29 AWD System 00 29 B Battery i secs echaroswvee wae kera 92 97 Charging Conventional 96 Charging Sealed 96 97 Fluid Conventional 95 Installation 94 Removal is sies aa id 93 StOTAQET sia ee Leli pa 95 BOOt8x si ita i bt das 19 Brake Fluid 70 71 Brake Inspections 72 Brake Lever ii aj 23 Brake Foot 25 Brake Parking 24 Brakelight 0 84 Brakes L A geen Ma ee eee 72 Break In Period 33 34 Breather Filter 82 c Camber Adjustment 74 Carburetor onunu unanunua 76 Carburetor Adjustment 76 CUPO aa sna AEn e een ees 50 51 Caster Adjustment 74 Chokes a e E aE A E a h 26 Chrome Wheel Care 100 Cleaning and Storage 98 103 Clothing a se akosi gale de 19 Clutching Chart 2X4 111 Clutching Chart 4X4 113 Cold Weather Operation 37 Corrosion Removal Chrome 100 D Demand Drive Fluid 67 69 Drive Belt Wear Bum 106 Drivetrain Break In 34 Driving Downhill 43 Driving in Reverse 49 Driving on
2. 80 123
3. 100 RECYCLED The text is printed on 100 recycled with 40 post consumer waste PCW antone AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ED ALWAVS USE NEVERUSE NEVERCARRV NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS PELARIS For your nearest Polaris dealer The Way Out visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 U S A Part No 9922362 Rev 02 Printed in U S A WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory Motorcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but inform
4. 4 Remove the drain screw on the bottom of the recoil housing 5 Reinstall the drain screw Tip Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crankcase drain is opened 85 MAINTENANCE Spark Plugs Spark Plug Recommendations A Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 110 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification Plug Condition Torque Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft lbs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 87 A A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Remove the left side panel 2 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 3 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 86 MAINTENANCE Spark Plugs Spark Plug Inspection 4 Inspect the elect
5. CD 77 311 EEC driver perceived noise level 2004 108 EC as amended EMC Directive CISPR 12 2001 CAN CSA C108 4 M92 EN 55012 2002 EN 61000 6 2 2001 PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAME MODEL SOUND YEARS PRESSURE dB A __KA05__ OUTLAW 50 2008 2009 2010 76 8 _KA09__ OUTLAW 90 2008 2009 2010 76 8 FAO __ SPORTSMAN 90 2008 2009 2010 76 8 __VAIT__ RZR 170 2009 2010 81 3 __PB20 __ PHOENIX 200 2008 2009 2010 76 8 BA32 TRAIL BLAZER 330 2008 2009 2010 76 8 __CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 BASO SCRAMBLER 500 2008 2009 2010 79 6 GIA OUTLAW 450 2008 2009 2010 80 7 GJ52_ GPS OUTLAW 525 2008 2009 2010 80 7 __LH27__ SPORTSMAN 300 2008 2009 2010 81 1 LH SPORTSMAN 400 2008 2009 2010 80 2 MN50 SPORTSMAN 500 EFI 2008 2009 2010 80 4 ZN55 ZX55 SPORTSMAN 550 EFI 2009 2010 80 8 TN55 DN55 SPORTSMAN X2 TOURING 550 2010 77 2 ___MN76_ SPORTSMAN 800 2008 2009 2010 83 6 TN85__ DN85 SPORTSMAN X2 TOURING 850 2010 77 2 CL76 SPORTSMAN 800 6X6 2009 2010 80 1 ZN85_ __ZX85 SPORTSMAN 850 EFI 2009 2010 80 4 RH50 HH5O RANGER 500 EFI 4X4 2009 2010 76 5 __HH76 RANGER 800 EFI 4X4 2010 76 5 __WH76__ RANGER 800 EFI CREW 2010 76 5 HR RANGER 800 6X6 2010 76 5 HY _ RANGER HD 800 4X4 2010 76 5 __VH76_ RANGER RZR 2008 2009 2010
6. E Steering Pre Ride z Make adjustments as need gt Front suspension Pre Ride fdan Bee Checklist gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Headlamp tail Daily Check operation apply lamp dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element Recoil housing Weekly Drain water as needed if applicable check often if operating in wet conditions gt Brake pad wear 10H Monthly 100 160 Inspect periodically a Battery 20H Monthly 200 320 Check terminals clean test gt Front gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped gt Transmission oil 25H Monthly 250 400 Inspect level change yearly gt Engine breather 25H Monthly 250 400 Inspect clean if needed E filter if equipped gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 56 Periodic Maintenance Chart MAINTENANCE
7. 70 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 Tip Position the vehicle on a level surface Make sure the handlebars are straight View the fluid level through the indicator win dow eye on the top of the master cylinder The eye will appear dark when the fluid level is full When fluid is low the eye will be clear Add the recommended fluid as needed Do not overfill Foot Brake The brake fluid reservoir is located on the right side of the vehicle Maintain the fluid level between the minimum and maximum marks Do not overfill MAINTENANCE Master Cylinder Indicator Window 71 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar The auxiliary foot brake is also hydraulic Both brake systems are self adjusting Brake Inspections The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 70 2 Check the brake system for i fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the fri
8. Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt General 50 H 3M 500 800 JLubricate all fittings pivots lubrication cables etc Carburetor float 50H 6M 500 800 Drain bowl periodically and bowl prior to storage E Throttle Cable 50H 6M 500 800 Inspect adjust lubricate E JETC Switch replace if necessarv E Choke cable 50H 6M 500 800 jInspect adjust lubricate E replace if necessary E Carburetor air 50H 6M 500 800 jinspect duct for proper seal intake ducts flange ing air leaks Drive belt 50H 6M 500 800 Inspect adjust replace as needed gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at 20 hours P Oil filter change 100 H 6M 1000 1600 Replace with oil change gt Oil tank vent hose 100 H 6M 1000 1600 Inspect routing condition if equipped Valve clearance 100 H 12M 1000 1600 Inspect adjust E Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100H 12M 1000 1600 Inspect pipe Spark plug 100 H 12M 1000 1600 Inspect replace as needed Ignition Timing 100 H 12M 1000 1600 Inspect gt Wiring 100 H 12M 1000 1600 Inspect for wear routing securitv applv dielectric grease to connectors subjected to water mud etc 57 MAI
9. 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly 7 Do not use the override switch unless additional power is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed A Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage Operate the throttle just enough to maintain a desired speed 49 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo Read and understand the load distribution warnings listed on the vehicle warning labels Never exceed the stated load capacity for this vehicle REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING Use extreme caution when applying brakes Avoid situations that require backing downhill When operating over rough or hilly terrain reduce speed cargo and towed load to maintain stable driving conditions DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Carrying a load high
10. 7175374 16 SAFETY Safety Labels and Locations Clutch Cover Warning WARNING NO STEP e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed e Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death Rack Warning Front and Rear WARNING s DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch e Max Rack Loads Front 70 Ibs 32 kg Rear 100 Ibs 46 kg Reverse Override Warning 4X4 Models WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse Override Switch 2X4 Models Reverse speed is limited Reverse override is controlled by the override switch See your Owner s Manual All Wheel Drive Switch 4X4 Models Do not push switch to engage AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage See your Owner s Manual Hitch Capacity Label TRAILER MAX WEIGHT 750 LBS 340 KG ON LEVEL GROUND HITCH MAX VERTICAL WEIGHT 75 LBS 34 KG 17 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury ae Eye Protection Long Sleeves Gloves Long
11. Never operate this vehicle on a public street road or highway including a dirt or gravel road A Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting i A Hot components can cause serious burns and fire Do not touch hot exhaust svstem components Alwavs keep combustible materials awav from the exhaust svstem For more information about safetv contact an authorized Polaris dealer or visit the Polaris web site at www polarisindustries com 13 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If a label becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label The following pages repeat the information found on each label General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control AL
12. Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your 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 Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 92 Battery Battery Removal 1 2 Place the transmission in gear Lock the parking brake Open the front cover Disconnect the battery hold down strap On conventional batteries remove the battery vent tube Disconnect the black
13. engine strokes Tip The rope will be harder to pull when the engine is on a compression stroke When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 3 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 4 Repeat all steps until the engine starts 5 Make sure the handle is fully seated on the housing A Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 28 FEATURES AND CONTROLS All Wheel Drive AWD System 4X4 Models The All Wheel Drive system is controlled by the AWD switch When the switch is on 2X4 the vehicle is in two wheel drive at all times When the switch is on AWD the vehicle is in all wheel AWD drive and the AWD indicator light Switch in the instrument cluster will be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage Tip The override switch allows activation of AWD in reverse if the AWD switc
14. 45 L Lights sn eee ea 83 84 Headlamp Replacement 84 Headlight Beam Adjustment 83 Taillight Brakelight 84 Lubrication Guide 59 M Maintenance Chart 54 58 Mode Switch 20 Modifications 0 6 N Noise Emission Control System 53 0 Oil E BINEM LI aaa 60 61 Transmission 64 66 Oil and Filter Change 62 63 Oil Level Engine 61 Oil Recommendations 60 Operator Safety 8 13 Override Switch 20 122 P Parking Brake 24 Parking on an Incline 52 Periodic Maintenance Chart 54 58 Polaris Product List 105 Polishing the Vehicle 99 Pre Ride Checklist 35 PVT Break In 34 PVT Divini i sine eae 91 PVT Svstem 000000 90 91 R Recoil Housing 85 Recoil Starter 28 Reverse Operation 49 Reverse Override Switch 20 Rider Information Center 31 Riding Gear 18 19 S Safety Labels 14 17 No Passenger Warning 16 Age 16 Warning 16 All Wheel Drive Switch 17 Clutch Cover Warning 17 Discretionary Warning 15 General Waming 14 Hitch Capacity Label 17 Rack Warning Front and Rear 17 Reverse Override Warning 17 Tire Pressure
15. 74 in 188 cm Overall Width 42 in 107 cm Overall Height 45 5 in 116 cm Wheelbase 46 in 117 cm Ground Clearance 8 in 20 cm Minimum Turning Radius 62 5 in 159 cm unloaded Engine Model Number Type ES300PFE010 4 Cycle Single Cylinder Lubrication Wet sump Engine Cooling Air Displacement 299 cc Bore x Stroke 78 5 x 68 Alternator Output 250 w Compression Ratio 9 2 1 Carburetor Mikuni BST 34 Pilot Jet 45 Main Jet 140 Needle Jet 0 5M Jet Needle 4HC57 3 Pilot Air Jet 140 Ignition System DC CDI Ignition Timing 10 2 1500 RPM 30 2 5000 RPM Spark Plug Gap NGK CR8E 031 in 0 8 mm Driving System Type Automatic PVT Polaris Variable Transmission Shift Type Side Lever H N R Based on EU Directive 76 432 EC 112 SPECIFICATIONS HAWKEVE 4X4 Drive Ratio Front 3 6 1 Drive Ratio Final 15 18 1 Tires Pressure Standard models Front 22x7 12 5 psi 34 5 KPa Rear 22x10 12 5 psi 34 5 KPa Tires Pressure LE models Front 23x7 12 5 psi 34 5 KPa Rear 23x10 12 5 psi 34 5 KPa Front Suspension MacPherson strut with 7 18 cm travel Rear Suspension Progressive rate with 8 20 cm travel Shock Adjustment CAM Brakes Front and Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel
16. Batteries Electronic components e Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim e Spark Plugs e Lubricants such as oil grease etc e Filters e Batteries unless defective e Fuel Cosmetic damage repair Sealants Coolants Hotel fees e Meals e Towing charges Shipping handling fees e Mileage e Product pick up delivery e Rentals Loss of product use e Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a def
17. Load Warning 15 Safety Training 6 Severe USE sissies ena aie as 54 Side Panel Removal 78 Sidehilling L 42 Signal Words 5 Spark Arrestor 0 0 0000 89 Spark Arrestor Requirements 53 Spark Plu s 2 jon be sabet ny ea s 86 87 Spring Adjustments 74 Starting the Engine 36 37 Steering Assembly 78 Storage 98 103 S Switches AWD Switch 21 29 Engine Stop Switch 21 Headlight Switch 21 Main Key Switch 21 Mode Reverse Override Switch 20 T Taillight 00 84 Throttle Cable Freeplay 77 Throttle Lever 00 22 Tire Tread Depth 79 ANOS 5055055 la ba 79 81 Front Wheel Hub Tightening 79 Tread Depth 79 Wheel Installation 81 Wheel Nut Torque 81 Wheel Removal 80 Toe Alignment 73 Towing Loads 51 Training Safety 6 Transmission Oil 64 66 Transporting the Vehicle 104 Turning Around ona Hill 44 45 Turning the Vehicle 39 INDEX V Vehicle Identification Numbers 7 Vehicle Immersion 88 WwW Warning Symbols 5 Washing the Vehicle 98 99 Wheel Hub Tightening 79 Wheel Installation 81 Wheel Nut Torque Specifications 81 Wheel Removal
18. a Sidehill 42 Driving on Slippery Surfaces 40 Driving Over Obstacles 48 Driving Procedures 38 Driving Through Water 46 47 Driving Uphill 41 E Electromagnetic Interference 53 Electronic Throttle Control 22 Engaging AWD 29 Engine Break In 34 Engine Fogging 102 Engine Idle RPM Adjustment 76 Engine Oil 60 61 Equipment Modifications 6 Exhaust Emission Control System 53 Eye Protection 19 F Fluid Brakes asardir 70 71 Demand Drive 67 69 Engine Oil 60 Transmission Oil 64 Foot Brake Auxiliarv 25 Footwell Removal 78 Front Gearcase 67 69 Fuel Filter 00 2 2 26 Fuel Safety 005 32 Fuel Tank Cap 26 Buel Valve siegh sayru see ee 26 G Gear Selector 000000 27 Gloves oc gt ee L lee a 19 121 INDEX H Handlebar Adjustment 75 Hauling Cargo 50 51 Headlamp Replacement 84 Headlight Beam Adjustment 83 Headlight Switch 21 Helmet ASA oh N ciate 18 l Idle RPM Adjustment 76 Immersion LL rne eena 88 Instrument Cluster 30 31 J Jetting Chart 2X4 111 Jetting Chart 4X4 113 K Key Switch 4 21 K Turi as Dati Jecnueave ade 44
19. all grease fittings 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads 46 OPERATION Driving Through Water If it s unavoidable to enter water deeper than the footrest level e Proceed slowly Avoid rocks and obstacles e Balance your weight carefully Avoid sudden movements e Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes A If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine If it s impossible to take it to a dealer before starting it follow the steps described on page 88 Have the vehicle serviced by your dealer at the first opportunity 47 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 48 Alwavs check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantiv alert for haz ards such as logs rocks and low hanging branches Travel slowlv and use extra caution when operating on unfamiliar terrain Not all obstacles are immediatelv visible Never attempt to operate over large obstacles such as rocks or fallen trees OPERATION Driving in Reverse Follow these precautions when operating in reverse ae ote 1 Always check for obstacles or people a behind the vehicle
20. 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 Torque to specification See page 64 for recom mendations 65 MAINTENANCE Transmission Oil Oil Change 1 Position the vehicle on a level surface 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 drain plug Torque to specification See page 64 for recommendations 9 Add the recommended oil 10 Reinstall the fill plug Torque to specification See page 64 for recommenda tions 11 Check for leaks 8 12 Dispose of used oil properly 66 Front Gearcase Demand 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 We recommend the use of Polaris Premium Demand Drive Hub Fluid Use of other oils may result in improper operation of compo nents See page 105 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the gearcase The drain plug is located on the bot tom right side of the gearcase Demand Drive Fluid Recommen
21. conditions and your experience A Never attempt jumps or other stunts SAFETY Operator Safety Always inspect your vehicle before each use to verify that it s in safe operating condition Follow the inspection and maintenance procedures outlined in this manual See page 35 Keep both hands on the handlebars Keep both feet on the footrests A Always travel slowly when operating on unfamiliar terrain Use extra caution A Use caution when operating on rough slippery or loose terrain 10 SAFETY Operator Safety A Always follow the procedures outlined in this manual for turning Never turn sharply at excessive speeds which can lead to vehicle overturn See page 39 A If this vehicle has been involved in an accident always have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not limited to brake throttle and steering systems A Always follow the procedures outlined in this manual for driving on hills See page 41 Never operate on hills too steep for this vehicle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 15 Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 43 A Always follow the procedures outlined in this manual for crossing the side of a hill See page 42 Never attempt to turn this vehicle aro
22. filter After the filter contacts the engine surface turn it 1 2 turn by hand Remove the dipstick Add the recommended oil See page 60 Reinstall the dipstick Start the engine Allow it to idle for two minutes Stop the engine Check for oil leaks Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Safe Range Add Oil Safe Reinstall the dipstick Discard used oil and filter properly 63 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning 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 fender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission Premium AGL Synthetic 15 2 oz 15 ft Ibs 15 ft Ibs 2x4 Gearcase Lubricant 450 ml 20 Nm 20 Nm Transmission Premium AGL Synthetic 20 3 oz 15 ft Ibs 15 ft Ibs 4x4 Gearcase Lubricant 600 ml 20 Nm 20 Nm 64 MAINTENANCE Transmission Oil Oil Check 1 Position the vehicle on a level surface 2 Place the transmission in gear 3 Lock the parking
23. high speeds 39 OPERATION 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 when enter ing slippery areas 3 Engage AWD if equipped before wheels begin to lose traction NOTICE Severe damage to drive train may occur if the AWD is engaged while 40 the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Sideways Turn in skid 4 direction of C O C JITC SS 7 A raj lt gt lt 3 fa M C C C Y AS c WA OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected 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 follow these precautions Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose
24. nega tive battery cable first Disconnect the red posi tive battery cable last Lift the battery out of the vehicle Be careful not to tip MAINTENANCE a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 93 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 96 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte A Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Onconventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Sec
25. of which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 99 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 Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 40000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 100 MAINTENANCE Cleaning and Storage Storage Tips A Starting the engine duri
26. parking brake Remove the seat AWN 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 Wash the sleeve in soapy water then rinse and let dry 9 Remove the breather filter 10 Wash the breather filter in soapy water then rinse and let dry 11 Reinstall the breather filter A Operation of your vehicle without a breather filter can cause engine damage 12 Reinstall the sleeve over the air filter Replace the filter if needed 13 Reinstall the air filter into the air box 14 Reinstall the air box cover and the seat 82 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 25 ft 1 Position the vehicle on a level surface with the headlight approxi matelv 25 ft 7 6 m from a wall 2 Place the transmission in neutral 3 Lock the parking brake 4 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring 5 Start the engine Turn the headlight switch to high beam 6 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Loosen the phillips screw at the rear of the headlamp 8 Adjust the beam Tighten
27. speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Miles Kilometers Toggle The display in the tripmeter odometer and speedometer can be changed to display either kilometers or miles 1 To change modes press and release the mode button see page 31 as often as needed to reach the odometer mode 2 Inthe odometer mode press and hold the mode button until the let ters flash then release the button 3 Press and release the button one more time When the display stops flashing the mode has been set 30 FEATURES 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 Odometer Tripmeter Hour Meter Modes Use the reverse override mode button to toggle through the 3 standard modes Tip If using the mode button to program the rider information center or to toggle through the options the transmission cannot be in reverse Odometer The odometer records the distance traveled by the vehicle Trip Meter The trip meter records the distance traveled by the vehicle on e
28. surfaces Keep both feet on the footrests Shift your weight uphill Proceed at a steady rate of speed and throttle opening Never go over the top of any hill at high speed Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle OOO TILA a 41 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Hi o a 42 Slow down Avoid crossing the side of a steep hill Shift your weight uphill Keep your feet on the footrests If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately OPERATION Driving Downhill When driving downhill follow these precautions 1 DN g Ga Before operating your vehicle learn how to use the auxiliary brake for emergency situations if single lever brakes become inoperable Always check the terrain carefully before descending a hill Shift your weight uphill Drive straight downhill Slow down Squeeze the brake lever gradually 43 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 44 OPERATION Turning Aroun
29. the screw 83 MAINTENANCE Lights A Poor lighting can result in loss of control or an accident Lights become dirty during normal operation Wash the headlights and taillights frequently A Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled Headlamp Replacement When servicing a halogen 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 1 Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly 2 Remove the headlamp and install the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 From the rear of the brake light remove the two screws holding the lens E FE 36 cover in place Remove the lens cover 2 Remove the lamp and replace it with a new lamp 3 Test the light for proper operation 4 Reinstall the lens cover be Cover 84 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 hous ing is completely dry before reinstalling the drain plug 1 Place the transmission in gear 2 Lock the parking brake 3 Stop the engine
30. throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 91 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph 48 km h for one mile 1 6 km Operate 5 miles 8 km or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 34 106 Engine Doesn t Turn Over Possible Cause Blown fuse TROUBLESHOOTING Solution Replace fuse Low batterv voltage Recharge the batterv to 12 8 VDC Loose batterv connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on O
31. warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control 115 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items e Wheels and tires e Finished and unfinished surfaces Suspension components e Carburetor Throttle body components e Brake components Engine components Seat components e Drive belts e Clutches and components e Hydraulic components Steering components Circuit breakers Fuses e
32. 85 8 Authorized Signatory Aktavter 4 La Acer Alexander A Kennedv Product Compliance Polaris Industries Inc Engineering Operations 301 5th Avenue SW Roseau MN 56751 114 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris vehicle against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehcile is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your
33. Brake Parking Hydraulic lock all wheel Headlight 2 Single Beam on Bumper 37 5 watt Taillights 12V 8 26W Brake Light 12V 26 9W Battery 12V 14AH DC Plug In rear Accessory Windshield Accessory Speedometer Odometer Standard Tripmeter Hourmeter Fuel Gauge Standard Tool Kit Standard Jetting Chart ALTITUDE AMBIENT TEMPERATURE Meters Feet Below 40 F 40 F and above Below 5 C 5 C and above 0 900 0 3000 145 140 900 1800 3000 6000 Same main jet Remove 2 air box plugs 1800 2700 6000 9000 Same main jet Remove 4 air box plugs Above 2700 Above 9000 Same main jet Remove 6 air box plugs Above 3000 Above 10000 Same main jet Remove 6 air box plugs Move jet needle clip to position 2 Clutching Chart Altitude Roller Number of Rollers Driven Clutch Meters Feet Weight Spring 0 1500 0 5000 13 g 5412988 8 7043228 1500 3000 5000 10000 10 g 5412986 8 7043228 3000 10000 10 g 5412986 6 L 7043228 Remove two opposite rollers to maintain clutch balance 113 DECLARATION OF CONFORMITY Polaris Industries Inc 2100 Hwy 55 Medina MN 55340 U S A Telephone 763 542 0500 We Polaris Industries Inc declare that the vehicles listed below conform to the essential health and safety requirements applicable to off road all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 98 37 EC as amended Machinery Directive EN 1050 hazard analysis
34. Engine Serial Number Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Operator Safety AWARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual A Read and understand all warnings cautions and operating procedures in this manual and on the safety labels before operating this vehicle Never operate this vehicle without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris dealer or visit the Polaris web site at www polarisindustries com Never permit others to operate this vehicle unless they have read and understand this manual and all product labels and have completed a certified safety training course A Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers A Never allow anyone under 16 years of age to operate this vehicle SAFETY Operator Safety Always wear an approved helmet that fits properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants A Never consume alcohol or drugs before or while operating this vehicle A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating
35. NTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts E Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrestor 300 H 36M 3000 4800 Clean out Idle speed Adjust as needed E Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 58 Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 54 Items not listed in the chart should be lubricated at the General Lubrication interval MAINTENANCE Item Lube Method Engine Oil PS 4 PLUS Performance See page 60 Synthetic 2W 50 Brake Fluid DOT 4 Only See page 70 Transmission Oil Polaris AGL Synthetic See page 64 Gearcase Lube Front Demand Drive Unit Premium Demand Drive Hub See page 67 Front Gearcase if equipped Fluid Front Prop Shaft Yoke Control Arm front and rear Bearing Carrier Transmission upper pivot point Polaris Premiu
36. Pants Helmet Always wear a helmet that meets or exceeds established safety stan dards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label 18 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 or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 19 FEATURES AND CONTROLS Switches Headlight Switch Main Key Switch Mode Reverse Engine All Wheel Drive Switch oe Stop Switch 4X4 Models witch Mode Reverse Override Switch This vehicle is equipped with a reverse
37. See page 93 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 94 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the following guidelines for recharging A An overheated battery may explode causing severe injury or
38. WAYS use proper riding techniques to avoid vehicle overturns on hills and rough ter rain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 14 SAFETY Safety Labels and Locations Discretionary Warning WARNING e Never operate this ATV on HILLS steeper than 25 degrees 25 To prevent overturn on hilly ter rain use throttle and brakes grad ually and shift weight uphill e REVERSE operation can be dan gerous even at low speeds Steer ing becomes difficult To prevent loss of control avoid sudden brak ing or sharp turns 7175511 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death e Cold tire pressure Front 5 0 psi 34 5 kPa Rear 5 0 psi 34 5 kPa e Maximum weight capacity 385 Ibs 175 kg 7175442 15 SAFETY Safety Labels and Locations Age 16 Warning Rack Warning 7 No Passenger Warning Clutch Cover Warning No Passenger Warning WARNING NEVER ride as a passenger een can cause a loss of control resulting in SEVERE INJURY or 7175378 Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16
39. a tion about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Please see your dealer for all of your service needs during and after the warranty period For more information about Polaris visit us online at www polarisin dustries com POLARIS The Way Out POLARIS THE WAY OUT and HAWKEYE are registered trademarks of Polaris Industries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2010 HAWKEYE 2X4 Owner s Manual P N 9922362 2 TABLE OF CONTENTS Introduction 3 2 56 chs Maes Rect es ee era ot 5 Safety ia bia tame keane Dam A eee ae 8 Features and Controls 5055 20 Operation ii ii a a eee estas Sie 32 Emission Control Systems 53 Maintenance scutsshccas ceed i i ates 54 Polaris Products ii s00 since tre
40. ach trip if it s reset before each trip To reset the trip meter toggle to the trip meter mode Press and hold the mode button until the display changes to 0 In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter This mode logs the total hours the engine has been in operation 31 OPERATION Fuel Safety AWARNING Gasoline is highly flammable and explosive under certain conditions Use extreme caution whenever handling gasoline Refuel with the engine stopped Refuel outdoors or in a well ventilated area Never fill a fuel container while it s on the vehicle Static electricity between the rack and container could cause a spark Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Turn the fuel valve off whenever the vehicle is stored or parked 32 OPERATION Break In Period The break in period for your new Polaris vehicle is the first ten hours of operation or the time it takes to use the first two full tanks 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 in more e
41. anol content greater than 10 such as E 85 fuel Fuel Valve The fuel valve is located on the bottom of the fuel tank Access the fuel valve through the right front wheel well or from the front of the vehicle ON For normal operation OFF For vehicle storage and when transporting Refuel when the instrument gauge indicates a low fuel level Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 26 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear Gear selector is located on the Selector right side of the vehicle H High Gear N Neutral R Reverse Whenever this vehicle is left unattended always place the transmission in gear and lock the parking brake A Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage Stop the vehicle release the throttle and move the shift lever to the desired gear See your dealer if you experience any shifting problems 27 FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start Handle the engine use the recoil starter Follow the starting procedures on page 36 cranking the engine with the recoil starter instead of the main key switch Recoil Starter 1 Grasp the recoil starter rope handle tightly 2 Pull slowly so you can feel the
42. aris also has a wide range of additional accessories available for your vehicle Always install accessories that are approved for use with this vehicle Please see your Polaris dealer 103 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle Stop the engine Place the transmission in gear Lock the parking brake Turn the fuel valve off Secure the fuel cap oil cap and seat Remove the key to prevent loss during transporting SD PN Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 104 Part POLARIS PRODUCTS Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 2873603 Premium AGL Synthetic Gearcase Lube gal 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 02 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Pre
43. at range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your dealer Overuse of choke Inspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your dealer 108 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug L
44. before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts A Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 10 If a warm engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 11 If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in Cold Weather Operation If this vehicle is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accu mulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 37 OPERATION Drivi
45. c tion material is worn to 03 8 mm 5 Check the security and surface condition of the disc gt 03 8 mm 72 MAINTENANCE Toe Alignment A Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 3 6 mm toe out 1 Position the vehicle ona level surface 2 Place the handlebars ina straight ahead position 3 Tie a length of string between two stands as shown in the illustra tion Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 Ifyou discover improper alignment see your Polaris dealer for ser vice 73 MAINTENANCE 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
46. ccessory Windshield Accessory Speedometer Odometer Standard Tripmeter Hourmeter Fuel Gauge Standard Tool Kit Standard Jetting Chart ALTITUDE AMBIENT TEMPERATURE Meters Feet Below 40 F 40 F and above Below 5 C 5 C and above 0 900 0 3000 145 140 900 1800 3000 6000 Same main jet Remove 2 air box plugs 1800 2700 6000 9000 Same main jet Remove 4 air box plugs Above 2700 Above 9000 Same main jet Remove 6 air box plugs Above 3000 Above 10000 Same main jet Remove 6 air box plugs Move jet needle clip to position 2 Clutching Chart Altitude Roller Number of Rollers Driven Clutch Meters Feet Weight Spring 0 1500 0 5000 13 g 5412988 8 7043228 1500 3000 5000 10000 10 g 5412986 8 7043228 3000 10000 10 g 5412986 6 7043228 Remove two opposite rollers to maintain clutch balance 111 SPECIFICATIONS HAWKEYE 4X4 Gross Vehicle Weight 930 Ibs 422 kg Dry Weight 550 Ibs 250 kg Fuel Capacity 4 5 gal 171 Engine Oil Capacitv 2 qts 1 9 1 Transmission Oil 20 3 oz 600 ml Demand Drive Fluid 5 oz 148 ml Front Rack Capacitv 70 Ibs 32 kg Rear Rack Capacity 100 Ibs 45 kg Hitch Tongue Weight Capacity 75 Ibs 34 kg Rear rack capacity and tongue weight not to exceed 100 Ibs 45 kg Hitch Towing Rating 750 Ibs 340 2 kg Unbraked Trailer Towing Capacity 1213 Ibs 550 kg Overall Length
47. completely 7 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Safe Range 8 Reinstall the dipstick 61 MAINTENANCE Oil and Filter Change A Hot oil may result in serious burns Do not allow hot oil to contact skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 54 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface a ZA 2 OTO Place the transmission in neutral 3 Lock the parking brake 4 Start the engine Allow it to idle for two to three minutes Stop the engine 5 Clean the area around the drain plug Place a drain pan under the vehicle 7 Remove the drain plug Use a 6 mm Allen wrench 8 Drain the oil 9 Reinstall the drain plug with a new sealing washer gt Tip The sealing surfaces on the drain plug and q crankcase should be clean and free of burrs EN nicks or scratches o 10 Torque to specification See page 60 62 MAINTENANCE Oil and Filter Change 11 12 13 14 15 16 17 18 19 20 21 22 23 Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it Clean the filter sealing area on the engine Lubricate the filter o ring Check to make sure the o ring is in good condition Install the new oil
48. d on a Hill K Turn 1 2 3 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill Start the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the brake lever until the vehicle is on more level ground 45 OPERATION Driving Through Water Maximum Depth Your vehicle can operate through water 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 Avoid operating through deep or fast flowing water A Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart The following areas need special attention engine oil transmission oil front and rear gearcases and
49. dations MAINTENANCE Gearcase Lubricant Capacity FillPlug Drain Plug Torque Torque Demand Premium Demand Drive 5 oz 8 10 ft Ibs 8 10 ft Ibs Drive Unit Hub Fluid 148 ml 11 13 Nm 11 13 Nm if equipped 67 MAINTENANCE Front Gearcase Demand Drive Fluid if equipped 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 recommended oil as needed to bring the level to the bottom of the fill hole threads 7 Reinstall the fill plug 68 Torque to specification See page 67 MAINTENANCE Front Gearcase Demand Drive Fluid if equipped Fluid Change 1 Position the vehicle on a level surface 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 11 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 67 9 Add the recommended fluid 10 Reinstall the fill plug Torque to specification 11 Check for leaks 12 Dispose of used oil properly 69 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride Always maintain brake fluid at the recommended lev
50. death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 96 Battery MAINTENANCE Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging Charge Time State of Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 5 11 hours 50 75 12 0 12 5 volts Needs charge 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 97 MAINTENANCE Cleaning and Storage Washing the Vehicle 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 recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse
51. ditions of reduced visibility such as fog rain and darkness All Wheel Drive Switch 4x4 Models See page 29 for all wheel drive information 21 FEATURES AND CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever A a The throttle lever is spring Vi loaded Engine speed returns AI to idle when the lever is aa released Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Check the lever for proper operation before starting the engine Check occasionally during operation Do not start or operate a vehicle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Electronic Throttle Control ETC This vehicle is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease A The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 22 FEATURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes These brakes ar
52. e hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs A Operating this vehicle with a spongy brake lever can result in loss of braking which could cause an accident Never operate this vehicle with a spongy feeling brake lever 23 FEATURES AND CONTROLS Parking Brake A Operating this vehicle while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Locking the Parking Brake 1 Place the transmission in gear 2 Squeeze and release the brake lever two or three times then l squeeze and hold 3 Push the parking brake lock E forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards e The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling e Always block the wheels on the downhill side of this vehicle if leav ing it parked on a hill Another opti
53. e critical com ponent operations All service must be performed by your authorized Polaris dealer 79 MAINTENANCE Tires Wheel Removal 1 80 Position the vehicle on a level surface Place the transmission in gear Lock the parking brake Loosen the wheel nuts slightly Place a suitable stand under the footrest frame to raise the wheel slightly off the ground Remove the wheel nuts Remove the wheel MAINTENANCE Tires Wheel Installation A Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always 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 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 the ground 4 Torque the wheel nuts to specification Wheel Nut Torque Specifications 90 ft Ibs 122 Nm o ALUMINUM CAST Check the wheel nut torques occasionally and when they ve been loos ened for service Nut Type Nut Torque Lug Nut 90 ft Ibs 122 Nm 2 Piece Flange Nut 27 ft Ibs 37 Nm 81 MAINTENANCE Air Filter Breather Filter 1 Position the vehicle on a level surface Place the transmission in gear Lock the
54. e ee aout 105 Troubleshooting saaasnansnnnnnnn 106 Spe ifi ations swad istzkaoai ees ee bba 110 Declaration of Conformitv 114 Warranty 2933 uiec0t4ws50606 0 00 ta a 115 Maintenance Log 22 0000006 118 INDEX sii vee Ss Soe wwe DI eee eres ees 121 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to follow the warnings in this manual can result in serious injury or death This Polaris vehicle is not a toy and can be hazardous to operate A collision or rollover can occur quickly even during routine maneuvers if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating this Polaris ve
55. ect of materials or workmanship 116 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service yo
56. el Do not overfill The brakes should feel firm when they re applied Spongy or weak brakes may indicate a fluid leak or low fluid level A low fluid level may also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongy or weak brakes See your dealer for ser vice A Operating the vehicle with a spongy brake can result in loss of braking which could cause an accident Never operate the vehicle with spongy feeling brakes If the fluid level is low add DOT 4 brake fluid only See page 105 for the part numbers of Polaris products A An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion
57. fficient performance and longer life for these components Install the accessory oil cooler when the following conditions exist e The vehicle will be used for towing heavy loads e The vehicle will be used for dragging ground surfaces or performing similar activities e The vehicle is normally operated when the air temperature is above 100 F 38 C A Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use 33 OPERATION Break In Period Engine and Drivetrain Break in 1 3 Fill the fuel tank with gasoline See page 26 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 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling Vary the throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 35 Pull only light loads During the break in period change both the oil and the filter at 20 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in
58. goggles and 18 35 OPERATION Starting the Engine A 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 Tip Tip 7 Tip 36 Position the vehicle on a level surface Place the transmission in neutral Lock the parking brake The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged Turn the fuel valve on Sit on the vehicle Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled If the engine is cold pull the choke knob out until it stops The variable choke is fully on when the knob is pulled com pletely out The choke is off when the knob is pushed com pletely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components Move the engine stop switch to RUN Do not press the throttle while starting the engine OPERATION Starting the Engine 8 Turn 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 engine starts 9 Ifthe engine does not start return the key to the OFF position and wait five seconds
59. h is on See page 20 There is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD A Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 29 FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an B instrument cluster that senses be To from the nel front SS wheel The instrument cluster l measures distance in miles as well as hours of operation It also includes a reverse speed limiter function that limits this vehicle s speed to approximatelv 7 9 mph Refer to page 20 for additional information A High water pressure may damage vehicle components Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the
60. h a new filter 4 Remove the spark plug 5 Loosen the carburetor drain screw and drain the carburetor 6 Turn the engine over several times using the electric start 7 Dry the spark plug Reinstall the plug or install a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying proce dure 11 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not 12 If water has been ingested into the PVT follow the procedure on page 91 for drying out the PVT 88 MAINTENANCE Spark Arrestor A Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death The exhaust system can get extremely hot Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Lock the parking bra
61. hicle Safety Training When you purchased your new Polaris vehicle your dealer offered a hands on safety training course You were also provided with printed materials that explain safe operating procedures Review this informa tion on a regular basis If you purchased a used Polaris vehicle from a party other than a Polaris dealer please request free safety training from any authorized Polaris dealer Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Restrictions This vehicle is approved for OFF ROAD TOWING ONLY Towing a trailer with this vehicle on public roads is prohibited Equipment Modifications The warranty on your Polaris vehicle may be terminated if any equip ment has been added or if any modifications have been made that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers and large racks may change vehicle handling Use only Polaris approved accessories Know their function and effect on the vehicle INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number 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 your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost
62. ke y 4 Remove the arrestor y T clean out plug from the Clean Out Plug bottom of the muffler 5 Start the engine Exhaust Outlet 6 Quickly squeeze and release the throttle lever several times to purge carbon from the system 7 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 8 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 6 9 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 10 Repeat steps 6 to 8 until no more particles are expelled 11 Stop the engine Allow the arrestor to cool 12 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 89 MAINTENANCE PVT System A Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe e Always follow all recommended maintenance procedures See your dealer as outlined in the owne
63. lbase 46 in 117 cm Ground Clearance 8 in 20 cm Minimum Turning Radius 62 5 in 159 cm unloaded Engine Model Number Type ES300PFE010 4 Cycle Single Cylinder Lubrication Wet sump Engine Cooling Air Displacement 299 cc Bore x Stroke 78 5 x 68 Alternator Output 250 w Compression Ratio 9 2 1 Carburetor Mikuni BST 34 Pilot Jet 45 Main Jet 140 Needle Jet 0 5M Jet Needle 4HC57 3 Pilot Air Jet 140 Ignition System DC CDI Ignition Timing 10 2 1500 RPM 30 2 5000 RPM Spark Plug Gap NGK CR8EB 031 in 0 8 mm Driving System Type Automatic PVT Polaris Variable Transmission Shift Type Side Lever H N R Drive Ratio Final 15 18 1 Based on EU Directive 76 432 EC 110 SPECIFICATIONS HAWKEYE 2X4 Tires Pressure Front 22x7 12 5 psi 34 5 KPa Tires Pressure Rear 22x10 12 5 psi 34 5 KPa Front Suspension MacPherson strut with 7 18 cm travel Rear Suspension Progressive rate with 8 20 cm travel Shock Adjustment CAM Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 2 Single Beam on Bumper 37 5 watt Taillights 12V 8 26W Brake Light 12V 26 9W Battery 12V 14AH DC Plug In rear A
64. ld or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Overuse of choke Inspect plugs verify stop switch is on Inspect clean and or replace spark plugs Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectiv installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer 107 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel 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 Engine Runs Irregularly Stalls or Misfires Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or he
65. lean See page 101 2 Support the front end of the machine so the engine is level or tilted slightly rearward 3 Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of engine oil into the cylinder 4 Reinstall the spark plug Torque to specification 5 Apply dielectric grease to the inside of the spark plug cap Reinstall the cap 6 Turn the engine over several times using the recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 7 If Polaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline 102 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 54 Battery Storage See pages 95 96 for storage and charging procedures Storage Area Covers 1 Set the tire pressure and safely support the vehicle with the tires slightly off the ground Be sure the storage area is well ventilated 3 Cover the vehicle with a genuine Polaris cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Pol
66. m U Joint Lube Grease fittings 3 pumps maxi mum every 500 miles 800 km before long periods of storage or after pressure washing or submerging Front Prop Shaft Yoke Bearing Carrier O Transmission Upper Pivot Point 59 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing 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 Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation A Mixing brands or using a non recommended oil may cause serious engine damage Always use a recommended oil Never substitute or mix oil brands Oil Specifications Lubricant Capacity Drain Plug Torque PS 4 PLUS Performance 2 ats 1 9 1 14 ft Ibs 19 Nm Synthetic 2W 50 60 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the vehicle a 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Lock the parking brake 4 Start the engine Allow it MANU to idle for 30 seconds Dipstick Stop the engine 5 Remove the dipstick Wipe it dry with a clean cloth ues 6 Reinstall the dipstick
67. mium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOTA Brake Fluid 12 oz 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger 105 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range if equipped Starting out going up a steep incline Use low range if equipped or turn around using the K turn see page 44 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range if equipped more frequently Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only if equipped Utility use plowing Use low range only if equipped Stuck in mud or snow Climbing over large objects from a stopped position Shift the transmission to low range if equipped Care fully use fast aggressive
68. ng Procedures W 090 Ai na 38 Wear protective riding gear See page 18 Perform the pre ride inspection See page 35 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check vour surroundings and determine vour path of travel Release the parking brake Slowlv depress the throttle with vour right thumb and begin driving Drive slowlv Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Turning the Vehicle Your 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 slightly 1 Slow down 2 Steer in the direction of the turn 3 Keep both feet on the foot rests 4 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse 5 Practice making turns at slow speeds before attempting to turn at faster speeds Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at
69. ng the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 98 Stabilize the Fuel 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 62 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Clean or replace the breather filter 4 Drain the sediment tube Recoil Housing 1 Drain the recoil housing See page 85 101 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 54 e Demand drive unit front gearcase if equipped e Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated Fog the Engine 1 Treat the fuel system with Polaris Carbon C
70. on is to park in a sidehill position e Never depend on the parking brake alone if this vehicle is parked on a hill Always block the wheels to prevent rolling 24 FEATURES AND CONTROLS Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake A Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide side ways causing loss of control and serious injury or death The auxiliary foot brake is located on the inside of the right footrest Operate this brake with your right foot If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without Auxiliary Foot Brake skidding Check the brake fluid level frequently for the auxiliary brake system See page 71 25 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 36 for correct choke and throttle settings during start ing Fuel Tank 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 octane Do not use fuel with eth
71. on the rack raises the center of gravity of the vehicle and creates a less stable operating condition Reduce load weight when cargo is high Secure off centered loads that cannot be centered and operate with extra caution CARRYING A LOAD on only one rack may cause the vehicle to overturn Split the load between the front rack and rear rack with 1 3 in the front and 2 3 in the back Do not exceed load capacities SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehi cle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn TOWING is approved OFF ROAD ONLY Operating this vehicle with a trailer on public roads is prohibited TOWING SPEED should never exceed 16 km h Never exceed 8 km h when towing loads in rough terrain while cornering or while ascending or descend ing hills 50 OPERATION Hauling Cargo Your vehicle 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 o
72. oose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction Electronic throttle control malfunction See your dealer See your dealer Other mechanical failure See your dealer Engine Overheating Possible Cause Solution Towing dragging heavv loads Install the accessorv oil cooler if this Vehicle will be used for towing heavv loads dragging ground surfaces or per forming similar activities Operating in excessive heat Install the accessorv oil cooler if this vehicle is normally operated when air temperature is above 100 F 38 C 109 SPECIFICATIONS HAWKEYE 2X4 Gross Vehicle Weight 930 Ibs 422 kg Dry Weight 525 Ibs 238 kg Fuel Capacity 4 5 gal 17 D Engine Oil Capacitv 2 qts 1 9 1 Transmission Oil 15 2 oz 450 ml Front Rack Capacitv 70 Ibs 32 kg Rear Rack Capacity 100 Ibs 45 kg Hitch Tongue Weight Capacity 75 lbs 34 kg Rear rack capacity and tongue weight not to exceed 100 Ibs 45 kg Hitch Towing Rating 750 Ibs 340 2 kg Unbraked Trailer Towing Capacity 1213 Ibs 550 kg Overall Length 74 in 188 cm Overall Width 42 in 107 cm Overall Height 45 5 in 116 cm Whee
73. period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 34 Pre Ride Checklist OPERATION A If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition protective clothing Item Remarks Page Brake system lever travel Ensure proper operation 23 Brake fluid Ensure proper level 70 Auxiliary brake Ensure proper operation 25 Front suspension Inspect lubricate if necessary 59 Rear suspension Inspect lubricate if necessary 59 Steering Ensure free operation Tires Inspect condition and pressure 79 Wheels fasteners Inspect ensure fastener tightness E Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels o Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation ee Indicator lights switches Ensure operation 20 Engine stop switch Ensure proper operation 21 Air filter pre filter Inspect clean 82 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 21 tric grease when lamp is replaced 84 Brake light tail lamp Check operation apply Polaris dielec 84 tric grease when lamp is replaced Riding gear Wear approved helmet
74. r s manual e This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 90 MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before 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 drain com pletely Reinstall the drain plug 4 Start the engine Place the transmission in neutral 5 Apply varying throttle for 10 15 seconds to expel the mois ture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to set tle to idle speed then shift the transmission into forward gear 7 Test for belt slippage If the belt slips repeat the process 8 Take the vehicle to your dealer for service as soon as possible 91 MAINTENANCE Battery AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last A WARNING Battery electrolyte is poisonous It contains sulfuric acid
75. rodes for wear and carbon buildup Replace worn or fouled plugs Verify that the gap is at specification before ip oe installation 5 Reverse the procedure for spark plug installation Torque to specification Spark Plug Condition Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect throt tle body carburetor adjustments 87 MAINTENANCE Vehicle Immersion A If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 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 the water Turn the fuel valve off 3 Check the air box If water is present dry the air box and replace the filter wit
76. rvice and adjustment procedures have a qualified dealer perform these operations Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 54 MAINTENANCE Periodic Maintenance Chart AWARNING Improperly performing the procedures marked with a IM could result in component failure and cause an accident which may result in serious injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions M Have an authorized Polaris dealer perform these services 55 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km
77. se spring tension Always adjust both sides equally Tip Accessory springs are available through your Polaris dealer 74 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference A Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Loosen the four handlebar bolts 2 Adjust the handlebar to the desired height 3 Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will Handlebar remain at the rear bolts Bolts 75 MAINTENANCE Carburetor This vehicle is calibrated at the factory 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 higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient opera tion Optional jets a
78. speed limiter system To gain additional power while backing depress the override switch The override switch also allows activation of All Wheel Drive in reverse if the AWD switch is on This switch is also used to toggle through the modes of the rider information center See page 30 A Activating the override switch with the throttle open and while operating in reverse can cause loss of control Do not activate the override switch while the throttle is open 20 FEATURES AND CONTROLS Switches Engine Stop Switch lt gt Move the stop switch either left or right to the OFF position to p stop the engine quickly The OS engine will not start or run when OFF RUN OFF the switch is off Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 36 for starting pro cedures Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The lights won t work unless the key is in the ON position and the engine stop switch is in the RUN position A Operating this vehicle on streets or roads especially in darkness could result in an accident and serious injury or death Your vehicle is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in con
79. t Lock Nut Adjuster 77 MAINTENANCE Steering Assembly The steering assembly of this vehicle should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Side Panel Removal 1 Remove the seat 2 Grasp the top of the side panel and pull it outward to remove it Footwell Removal 1 Remove the two screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell Rivets 78 MAINTENANCE Tires AWARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death e Maintain proper tire pressure as described on the label on your vehicle and in the owner s manual Always use original equipment size and type when replacing tires e Make sure the wheels are installed properly e Always replace tires when the tread depth measures 1 8 3 mm or less Refer to the specifications section beginning on page 110 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm L when tread depth is worn to 1 8 3 mm or less OR AW Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention ar
80. u must take it to a Polaris dealer authorized to repair Polaris vehicles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 117 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 118 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 119 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS
81. und on any hill until you ve mastered on level ground the turning technique outlined in this manual 11 SAFETY Operator Safety A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill See page 44 A Always follow the procedures outlined in this manual for operating over obstacles See page 48 A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 40 A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 46 A Always follow the procedures outlined in this manual for driving in reverse See page 49 A Always use the size and type of tires specified for your vehicle Maintain the proper tire pressure 12 SAFETY Operator Safety Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking A Never operate this vehicle on a frozen body of water A Always avoid operating this vehicle on paved surfaces including sidewalks driveways parking lots and streets
82. ure the battery hold down strap QO ya Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 94 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 charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 105 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check Mark the battery fluid level often 9 Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery Lower Upper Mark YBI4 B tesar 4011359 W YUASA KANES aos TAW YB14 B2 Che saza MADE IN 95 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging
83. utlined in the specifi cations section of the owner s manual and on the safety labels Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Towing Loads Always attach a towed load to the hitch point If towing a load reduce rear rack cargo weight by the amount of tongue weight The combina tion of rear rack cargo weight and tongue weight must not exceed the rear rack capacity A Using an improper hitch or exceeding the Maximum maximum tongue weight capacity can result 6 3 4 17 cm in serious damage to the vehicle and will void your warranty Never install a hitch longer than 6 3 4 17 cm Never install d a te sa your raa HH vehicle Always install Polaris approved or T b i equivalent accessories designed for use on your vehicle 51 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine Place the transmission in gear Always block the rear wheels on the downhill side 2 3 Lock the parking brake 4 5 Turn the fuel valve off 52 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with go
84. vailable from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting for conditions in your area Carburetor Engine Idle RPM Adjustment If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Place the transmission in gear 2 Lock the parking brake 3 Start the engine and allow it to warm up for approximately five minutes 4 Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM Idle Adjuster 76 Throttle Cable Freeplay MAINTENANCE Adjust throttle cable freeplay at the handlebar 1 2 Locate the throttle cable adjuster at the handlebar Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth Tighten the lock nut Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position NA Boo
85. vernmental noise level requirements Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on road and off road operation It is required that this spark arrestor remain installed and functional when the vehicle is operated Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC 53 MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions Vehicles subjected to severe use must be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 118 Service and adjustments are important for proper vehicle operation If you re not familiar with safe se
86. with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 98 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the follow ing items e Wheel bearings e Transmission seals e Brakes e Cab and body panels e Electrical components e Switches and controls e Labels and decals If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some

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