1
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.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Quadricycles
• RANGER utility vehicles
• Victory motorcycles
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but informa-
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.
2
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
Copyright 2007 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.
2008 Hawkeye 2X4 Owner’s Manual
P/N 9921770
3
TABLE OF CONTENTS
Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Emission Control Systems . . . . . . . . . . . . . . . 53
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 105
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 106
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 110
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 117
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4
5
KNOW YOUR VEHICLE
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment. Read
and understand your owner's manual, which includes valuable informa-
tion about all aspects of your vehicle, including safe operating proce-
dures.
Ride responsibly. Know all laws and regulations concerning the opera-
tion of this vehicle in your area.
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.
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
####
VIN
Engine Serial Number
Key Number
6
SAFETY
Operator Safety
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.
The safety alert symbol, on your vehicle or in this manual, alerts you to the
potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious
injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may result in minor
injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE
A note will alert you to important information or instructions.
7
SAFETY
Operator Safety
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 your 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.
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.
NOTE: The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers and large racks may change vehicle han-
dling. Use only Polaris-approved accessories. Know their function and
effect on the vehicle.
WARNING
Failure to follow the warnings in this manual can result in serious injury or
death. This 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 vehicle.
8
SAFETY
Operator Safety
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 under-
stand this manual and all product labels, and have completed a certified safety
training course.
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.
Never allow anyone under 16 years of age to
operate this vehicle.
WARNING
Serious injury or death can result if you do not follow the instructions and pro-
cedures listed here and throughout this manual.
9
SAFETY
Operator Safety
Always wear an approved helmet
that fits properly. Wear eye protec-
tion (goggles or face shield),
gloves, boots, long sleeves and
long pants.
Never consume alcohol or drugs before
or while operating this vehicle.
Never operate at excessive speeds. Travel
and turn at speeds appropriate for the ter-
rain, visibility, operating conditions and
your experience.
Never attempt jumps or other stunts.
10
SAFETY
Operator Safety
Always inspect your vehicle before
each use to verify that it's in safe oper-
ating 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.
Always travel slowly when operating on
unfamiliar terrain. Use extra caution.
Use caution when operating on rough,
slippery or loose terrain.
11
SAFETY
Operator Safety
Always follow the procedures outlined in this man-
ual for turning. Never turn sharply at excessive
speeds, which can lead to vehicle overturn. See
page 41.
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 sys-
tems.
Always follow the procedures outlined in this man-
ual for driving on hills. See page 43. Never operate
on hills too steep for this vehicle or for your abili-
ties. Practice on smaller hills before attempting
larger hills. Avoid climbing hills steeper than 15°.
Always follow the procedures outlined in this man-
ual for driving downhill and for braking on hills. See
page 45.
Always follow the procedures outlined in this manual
for crossing the side of a hill. See page 44. Never
attempt to turn this vehicle around on any hill until
you've mastered (on level ground) the turning tech-
nique outlined in this manual.
12
SAFETY
Operator Safety
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 46.
Always follow the procedures outlined in this manual for operating over obsta-
cles. See page 50.
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
42.
Always follow the procedures outlined in
this manual for driving through water.
Never drive through deep or fast-flowing
water. See page 48.
Always follow the procedures outlined in this manual for driving in reverse. See
page 51.
Always use the size and type of tires
specified for your vehicle. Maintain the
proper tire pressure.
13
SAFETY
Operator Safety
Never modify this vehicle through
improper installation or use of acces-
sories.
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.
Never operate this vehicle on a frozen body of water.
Always avoid operating this vehicle on paved surfaces, including sidewalks,
driveways, parking lots and streets. Never operate this vehicle on a public
street, road or highway, including a dirt or gravel road.
Always remove the ignition key when
the vehicle is not in use to prevent
unauthorized use or accidental start-
ing.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about safety, contact an autho-
rized Polaris dealer or visit the Polaris web site at
www.polarisindustries.com.
14
SAFETY
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions of the decals on the vehicle carefully. If
any of the decals depicted in this manual differ from the decals on your
vehicle, always read and follow the instructions of the decals on the
vehicle.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
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:
• 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:
• 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.
IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A
REPLACEMENT.
7172560
+
15
SAFETY
Safety Decals and Locations
Discretionary Warning
WARNING
• Never operate this ATV on
HILLS steeper than 25 degrees
25°. To prevent flip-over on
hilly terrain, when going up or
down, use throttle and brakes
gradually.
• REVERSE operation can be
dangerous even at low speeds.
Steering becomes difficult. To
prevent flipover, avoid sudden
braking or sharp turns.
• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of
control, never activate override button with open throttle.
• PARKING BRAKE may relax when used for more than 5 minutes. When park-
ing on grades, leave shift in forward.
7172665
Tire Pressure/Load Warning
WARNING
IMPROPER TIRE PRESSURE OR
OVERLOADING can cause loss of
control resulting in SEVERE INJURY
OR DEATH.
TIRE PRESSURE IN PSI (KPa):
FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY
365 lbs. (166 kg)
INCLUDES WEIGHT OF OPERA-
TOR, CARGO AND ACCESSORIES.
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered, carried as low as possible, and
firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is
best. For stability on rough or hilly terrain, reduce speed and cargo. Do not block
headlight. Be careful if load extends over the side of the rack.
Read Owner's Manual for more detailed loading information.
7174823
+
+
16
SAFETY
Safety Decals and Locations
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or
DEATH.
7172566
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.
7172559
+
“No Passenger”
Warning
+
Clutch Cover
Warning
+
Age 16 Warning
+
+
Rack
Warning
Rack
Warning
17
SAFETY
Safety Decals and Locations
Clutch Cover Warning
WARNING
NO STEP
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• 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
• 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.
• Max Rack Loads: Front 70 lbs. (32 kg) Rear 100 lbs. (46 kg)
Reverse Override Warning (4X4 Models)
WARNING
Pushing reverse override button may cause sudden increases in power and
traction if too much throttle is applied. Loss of control or forward flipover may
result, especially in AWD. See Owner's Manual.
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)
18
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Always wear a helmet that meets or exceeds established safety stan-
dards.
Approved helmets in the USA and 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
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
19
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. When-
ever riding a Polaris vehicle, always wear shatterproof 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.
20
FEATURES AND CONTROLS
Switches
Mode/Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system.To gain
additional power while backing, depress the override switch.
NOTE: 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.
WARNING
Activating the override switch while the throttle is open can cause loss of con-
trol, resulting in severe injury or death. Do not activate the override switch
while the throttle is open.
Mode/Reverse
Override
Switch
Main Key Switch
Engine
Stop Switch
Headlight
Switch
All Wheel Drive Switch
(4X4 Models)
21
FEATURES AND CONTROLS
Switches
Engine Stop Switch
Move the stop switch either left
or right to the OFF position to
stop the engine quickly. The
engine will not start or run when
the switch is off.
NOTE: 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.
NOTE: The lights won't work unless the key is in the ON position and the
engine stop switch is in the RUN position.
All Wheel Drive Switch (4x4 Models)
See page 29 for all wheel drive information.
WARNING
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 conditions of reduced visibility such as fog, rain and darkness.
OFF OFFRUN
22
FEATURES AND CONTROLS
Throttle Lever
Engine speed and vehicle move-
ment are controlled by pressing the
throttle lever. The throttle lever is
spring loaded. Engine speed returns
to idle when the lever is released.
This 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.
WARNING
Operating this vehicle with sticking or improperly operating throttle controls
could cause an accident and lead to severe injury or death.
Never start or operate this vehicle with a sticking or improperly operating
throttle. Always contact your dealer for service if throttle problems arise.
Failure to check or maintain proper operation of the throttle system can result
in an accident if the throttle lever sticks during operation. Always check the
lever for free movement and return before starting the engine. Also check
occasionally during operation.
WARNING
Modifications to the ETC could result in failure to perform as designed, which
could result in severe injury or death. Do not attempt to modify the ETC sys-
tem or replace it with any after market throttle mechanisms. Always ensure
that the throttle cable is properly installed to the ETC.
23
FEATURES AND CONTROLS
Brake Lever
Squeeze the brake lever toward the
handlebar to apply the front and
rear brakes. These brakes are
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.
WARNING
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.
24
FEATURES AND CONTROLS
Parking Brake
Locking the Parking Brake
1. Place the transmission in
gear.
2. Squeeze and release the brake
lever two or three times, then
squeeze and hold.
3. Push the parking brake lock
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
Important Safeguards
• The parking brake may relax if left on for a long period of time.
Always block the wheels to prevent rolling.
• Always block the wheels on the downhill side of this vehicle if leav-
ing it parked on a hill. Another option is to park in a sidehill position.
• Never depend on the parking brake alone if this vehicle is parked on a
hill. Always block the wheels to prevent rolling.
WARNING
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.
25
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.
The auxiliary foot brake is
located on the inside of the
right footrest. Operate this
brake with your right foot.
NOTE: If the rear wheels slide
while using the auxiliary
brake, reduce brake
pedal pressure to brake
the rear wheels without
skidding.
Check the brake fluid level frequently for the auxiliary brake system.
See page 71.
WARNING
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.
Auxiliary Foot Brake
26
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 gaso-
line with a minimum pump
octane number of 87=(R+ M/2)
octane. Do not use 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.
Fuel Tank
Cap
ON OFF
27
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear
selector is located on the
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.
CAUTION
Shifting gears with the engine speed above idle or while the vehicle is moving
could cause transmission damage.
To change gears, stop the vehicle, and with the engine idling, move the lever
to the desired gear.
Gear
Selector
28
FEATURES AND CONTROLS
Recoil Starter
If the battery is too weak to start
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.
1. Grasp the recoil starter rope
handle tightly.
2. Pull slowly so you can feel
the engine strokes.
NOTE: 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.
CAUTION
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.
Recoil Starter
Handle
29
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
drive and the AWD indicator light
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.
NOTE: The override switch allows activation of AWD in reverse if the AWD
switch 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.
CAUTION
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.
AWD
Switch
30
FEATURES AND CONTROLS
Instrument Cluster
Your vehicle is equipped with an
instrument cluster that senses
vehicle speed from the right front
wheel. The instrument cluster
measures distance in miles as
well as hours of operation. It also
includes a reverse speed limiter
function that limits this vehicle's
speed to approximately 7-9 mph.
Refer to page 20 for additional
information.
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. In the 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.
CAUTION
High water pressure may damage vehicle components. Wash this vehicle by
hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will damage the
speedometer lens and other plastic surfaces. Do not use alcohol to clean the
instrument cluster. Do not allow insect sprays to contact the lens. Immedi-
ately clean off any gasoline that splashes on the instrument cluster.
31
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.
NOTE: 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 each 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.
1
2
3
4
32
OPERATION
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is 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.
• Never start the engine or let it run in an enclosed area. Engine exhaust
fumes are poisonous and can cause loss of consciousness or death in a
short time.
• Turn the fuel valve off whenever the vehicle is stored or parked.
WARNING
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
33
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 efficient performance and longer life for
these components.
Install the accessory oil cooler when the following conditions exist:
• The vehicle will be used for towing heavy loads.
• The vehicle will be used for dragging ground surfaces or performing
similar activities.
• The vehicle is normally operated when the air temperature is above
100° F. (38° C).
CAUTION
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.
34
OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 26.
2. Check the oil level on the dipstick. See page 61. Add oil if neces-
sary to maintain the level between the safe and add marks.
3. Drive slowly at first. Select an open area that allows room to famil-
iarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 35.
6. Pull only light loads.
7. 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 period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur-
ing the break-in period.
35
OPERATION
Pre-Ride Checklist
WARNING
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.
Item Remarks Page
Brake system/lever travel Ensure proper operation 23
72
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 75
Wheels/fasteners Inspect, ensure fastener tightness 75
77
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 26
61
Coolant level (if applicable) Ensure proper level -
Coolant hoses (if applicable) Inspect for leaks -
Throttle Ensure proper operation 22
104
Indicator lights/switches Ensure operation 20
Engine stop switch Ensure proper operation 21
Air filter, pre-filter Inspect, clean 78
Air box sediment tube Drain deposits whenever visible -
Headlamp Check operation, apply Polaris dielec-
tric grease when lamp is replaced
21
80
Brake light/tail lamp Check operation, apply Polaris dielec-
tric grease when lamp is replaced
80
Riding gear Wear approved helmet, goggles, and
protective clothing
18
36
OPERATION
Starting the Engine
1. Position the vehicle on a level surface.
2. Place the transmission in neutral.
3. Lock the parking brake.
NOTE: The starter interlock will prevent the engine from starting if the trans-
mission is in gear and the brake is not engaged.
4. Turn the fuel valve on.
5. Sit on the vehicle.
NOTE: Do not use the choke if starting a warm engine. Excessive use of the
choke can cause the spark plug to become wet fouled.
6. If the engine is cold, pull the
choke knob out until it stops.
NOTE: The variable choke is fully
on when the knob is pulled
completely out. The choke
is off when the knob is
pushed completely in. The
choke can be adjusted
gradually, depending on
how much choke is needed
for starting. Be sure the
choke is off during opera-
tion, as excess fuel wash-
ing into the engine oil will
increase wear on engine
components.
7. Move the engine stop switch to RUN.
NOTE: Do not press the throttle while starting the engine.
WARNING
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.
Choke
Knob
37
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. If the engine does not start, return the key to the OFF position and
wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.
NOTE: 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 nec-
essary. 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.
10. 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.
CAUTION
Operating the vehicle immediately after starting could cause engine damage.
Allow the engine to warm up for several minutes before operating the vehicle.
38
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 outlined in the specifi-
cations section of the owner's manual and on the safety decals.
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.
CAUTION
Using an improper hitch or exceeding the
maximum tongue weight capacity can
result in serious damage to the vehicle
and will void your warranty. Never install
a hitch longer than 6 3/4" (17 cm). Never
install automotive accessories on your
Polaris vehicle. Always install Polaris-
approved (or equivalent) accessories
designed for use on your vehicle.
1/3
2/3
Maximum
6 3/4" (17 cm)
39
OPERATION
Hauling Cargo
WARNING
Hauling cargo improperly can alter vehicle handling and may cause loss of
control or brake instability and result in serious injury or death. Always follow
these precautions when hauling cargo:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on
the rear rack. When operating over rough or hilly terrain, reduce speed and
cargo to maintain stable driving conditions. Carrying loads on only one rack
increases the possibility of vehicle overturn.
CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads
high on the racks raises the center of gravity of the vehicle and creates a less
stable operating condition.
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.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
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.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on
the front rack.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 mph (16 kph) while towing a load on a level surface.
Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.
40
OPERATION
Driving Safely
Driving Procedures
1. Wear protective riding gear. See page 18.
2. Sit upright with both feet on the footrests and both hands on the
handlebars.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear.
5. Check your surroundings and determine your path of travel.
6. Release the parking brake.
7. Slowly depress the throttle with your right thumb and begin driving.
8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
41
OPERATION
Driving Safely
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.
To turn, steer in the direction of
the turn, leaning your upper
body to the inside of the turn
while supporting your weight
on the outer footrest. This tech-
nique alters the balance of trac-
tion between the rear wheels,
allowing the turn to be made
smoothly. The same leaning
technique should be used for
turning in reverse.
NOTE: Practice making turns at slow speeds before attempting to turn at
faster speeds.
WARNING
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 high
speeds.
42
OPERATION
Driving Safely
Driving on Slippery Surfaces
Whenever riding on slippery
surfaces such as wet trails or
loose gravel, or during freez-
ing weather, follow these
precautions:
1. Slow down when enter-
ing slippery areas.
2. Engage AWD before
wheels begin to lose
traction.
3. Maintain a high level of
alertness, reading the
trail and avoiding quick,
sharp turns, which can
cause skids.
4. Correct a skid by turning the handlebars in the direction of the skid
and shifting your body weight forward.
CAUTION
Severe damage to drive train may occur if the AWD is engaged while the
wheels are spinning. Always allow the rear wheels to stop spinning before
engaging AWD, or engage AWD before wheels begin to lose traction.
WARNING
Failure to exercise care when operating on slippery surfaces can result in
loss of tire traction and cause loss of control, accident, and serious injury or
death.
Never apply the brakes during a skid. Do not operate on excessively slippery
surfaces. Always reduce speed and use additional caution.
43
OPERATION
Driving Safely
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Drive straight uphill.
2. Avoid steep hills (25° maximum).
3. Keep both feet on the footrests.
4. Shift your weight uphill.
5. Proceed at a steady rate of speed and throttle opening.
6. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.
WARNING
Braking and handling are greatly affected when operating in hilly terrain.
Improper procedure could cause loss of control or overturn and result in seri-
ous injury or death.
Avoid climbing steep hills (25° maximum).
Use extreme caution when operating on hills, and follow proper operating
procedures outlined in the owner's manual.
25° Maximum
44
OPERATION
Driving Safely
Driving on a Sidehill (Sidehilling)
Sidehilling can be dangerous and should be avoided if at all possible. If
you encounter a situation where sidehilling is necessary, follow these
precautions:
1. Slow down.
2. Shift your weight uphill.
3. Keep your feet on the footrests.
4. Steer slightly into the hill to maintain vehicle direction.
NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if pos-
sible, or dismount on the uphill side immediately!
WARNING
Improperly crossing hills or turning on hills can result in loss of control or
vehicle overturn, resulting in severe injury or death. Avoid crossing the side
of a hill when possible. Follow proper procedures as outlined in the owner's
manual.
45
OPERATION
Driving Safely
Driving Downhill
When driving downhill, follow these precautions:
1. Shift your weight uphill.
2. Drive straight downhill.
3. Slow down.
4. Squeeze the brake lever gradually.
NOTE: Before operating your vehicle, learn how to use the auxiliary brake for
emergency situations (if single-lever brakes become inoperable).
WARNING
Excessive speed when traveling downhill can cause loss of control and seri-
ous injury or death. Slow down.
Applying the brakes too firmly may cause the rear wheels to lock, which
could result in loss of control and serious injury or death. Apply the brakes
gradually.
46
OPERATION
Driving Safely
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.
8 ft. (2.4 m)
47
OPERATION
Driving Safely
Turning Around on a Hill (K-Turn)
1. Stop and lock the parking brake while keeping body weight uphill.
2. Leave the transmission in forward and shut off the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the vehi-
cle is pointing straight uphill.
4. Staying uphill of the vehicle, turn the handlebars full left.
5. 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.
6. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill.
7. Start the engine with the transmission still in forward.
8. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.
48
OPERATION
Driving Safely
Driving Through Water
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. Proceed slowly, avoiding rocks and obstacles.
4. After crossing, dry the brakes by applying light pressure to the lever
until braking action is normal.
Maximum Depth
49
OPERATION
Driving Safely
Driving Through Water
After running the vehicle in water, it's critical to have it serviced as out-
lined in the maintenance chart. See page 54. The following areas need
special attention: engine oil, transmission oil, front and rear gearcases,
and all grease fittings.
NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you
cannot avoid water that exceeds the recommended maximum depth,
go slowly, balance your weight carefully, avoid sudden movements,
and maintain a slow and steady forward motion. Do not make sudden
turns or stops, and do not make sudden throttle changes.
If your vehicle becomes immersed, and it's impossible to take it to a
dealer before starting it, follow the steps described on page 84. Have the
vehicle serviced by your dealer at the first opportunity.
CAUTION
Major engine damage can result if the vehicle is not thoroughly inspected
after operation in water. Perform the services outlined in the maintenance
chart.
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.
50
OPERATION
Driving Safely
Driving Over Obstacles
Be alert! Look ahead and learn to read the terrain you're traveling on. Be
constantly alert for hazards such as logs, rocks and low hanging
branches.
WARNING
Severe injury or death can result if your vehicle comes in contact with a hid-
den obstacle. Not all obstacles are immediately visible. Travel with caution in
unfamiliar terrain.
51
OPERATION
Driving Safely
Driving in Reverse
Follow these precautions
when operating in reverse:
1. Always check for
obstacles or people
behind the vehicle.
2. Always avoid backing
downhill.
3. Back slowly.
4. Apply the brakes
lightly for stopping.
5. Avoid turning at sharp
angles.
6. Never open the throttle suddenly.
NOTE: Your Polaris vehicle is equipped with a reverse speed limiter. Use the
override button with caution as rearward vehicle speed is greatly
increased. Do not operate at wide open throttle.
WARNING
Failure to use caution when operating in reverse can result in serious injury
or death. Before shifting into reverse, always check for obstacles or people
behind the vehicle. When it's safe to proceed, back slowly.
Do not use the override switch unless additional power is required for vehicle
movement. Use with caution.
Avoid backing on inclines, and avoid turning at sharp angles.
CAUTION
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.
52
OPERATION
Driving Safely
Parking on an Incline
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Stop the engine.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
5. Turn the fuel valve off.
53
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with governmental noise level requirements.
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 USA requirements, Canadian
ICES-002 and European directives 89/336/EEC and 97/24/EC.
54
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
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 117.
NOTE: Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have
a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour (16 km/h). Vehicles subjected to severe use must be
inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• 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.
55
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
X 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.)
Q Have an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a Q could result in com-
ponent failure and lead to serious injury or death. Have an authorized Polaris
dealer perform these services.
56
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Q Steering - Pre-Ride - Make adjustments as need
ed. See Pre-Ride Checklist
on page 35.
X Front suspension - Pre-Ride -
X Rear suspension - Pre-Ride -
Tires - Pre-Ride -
X Brake fluid level - Pre-Ride -
X Brake lever travel - Pre-Ride -
Brake system - Pre-Ride -
Wheels/fasteners - Pre-Ride -
Frame fasteners - Pre-Ride -
X Engine oil level - Pre-Ride -
X
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
X Air box sediment
tube
- Daily - Drain deposits when visible
Headlamp/tail
lamp
- Daily - Check operation; apply
dielectric grease if replacing
X
E
Air filter,
main element
- Weekly - Inspect; replace as needed
Recoil housing
(if applicable)
- Weekly - Drain water as needed,
check often if operating in wet
conditions
X
Q
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
X Front gearcase oil
(if equipped)
25 H Monthly 250 (400) Inspect level; change yearly
X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly
X
E
Engine breather
filter (if equipped)
25 H Monthly 250 (400) Inspect; clean if needed
57
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
X General
lubrication
50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Carburetor float
bowl
50 H 6 M 500 (800) Drain bowl periodically and
prior to storage
Q
E
Throttle Cable/
ETC Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
Q
E
Choke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E Carburetor air
intake ducts/flange
50 H 6 M 500 (800 Inspect duct for proper seal-
ing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as
needed
X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change
at 20 hours
X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change
X Oil tank vent hose
(if equipped)
100 H 6 M 1000 (1600) Inspect routing, condition
Q
E
Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust
Q
E
Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
X Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
Q
E
Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
Q
E
Ignition Timing 100 H 12 M 1000 (1600) Inspect
X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
58
MAINTENANCE
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Q Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
Q Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
Q Brake fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrestor 300 H 36 M 3000 (4800) Clean out
Idle speed - Adjust as needed
Q Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
59
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 54. Items not
listed in the chart should be lubricated at the General Lubrication
interval.
Item Lube Method
Engine Oil PS-4 PLUS Performance
Synthetic 2W-50
See page 60.
Brake Fluid DOT 4 Only See page 70.
Transmission Oil Polaris AGL Synthetic
Gearcase Lube
See page 64.
Front Demand Drive Unit
(Front Gearcase)
Premium Demand Drive Hub
Fluid
See page 67.
Front Prop Shaft Yoke
Polaris Premium 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.
Control Arm (front and
rear)
Bearing Carrier
Transmission (upper
pivot point)
Front Prop Shaft Yoke
Bearing
Carrier
Control Arms
Transmission Upper
Pivot Point
60
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.
Oil Specifications
CAUTION
Mixing brands or using a non-recommended oil may cause serious engine
damage. Always use the recommended oil. Never substitute or mix oil
brands.
Lubricant Capacity Drain Plug Torque
PS-4 PLUS Performance
Synthetic 2W-50
2 qts. (1.9 l) 14 ft. lbs. (19 Nm)
61
MAINTENANCE
Engine Oil
Oil Level
The oil dipstick is located behind the
recoil on the right side of the vehicle.
1. Position the vehicle on a level
surface.
2. Place the transmission in neutral.
3. Lock the parking brake.
4. Start the engine. Allow it
to idle for 30 seconds.
Stop the engine.
5. Remove the dipstick.
Wipe it dry with a clean
cloth.
6. Reinstall the dipstick
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.
8. Reinstall the dipstick.
Dipstick
Safe
Add Oil
Safe Range
{
62
MAINTENANCE
Oil and Filter Change
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.
2. 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.
6. 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.
NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of
burrs, nicks or scratches.
10. Torque to specification. See page 60.
CAUTION
Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin.
63
MAINTENANCE
Oil and Filter Change
11. Place towels under the oil filter.
Using an oil filter wrench, turn the
filter counterclockwise to remove
it.
12. Clean the filter sealing area on the
engine.
13. Lubricate the filter o-ring. Check
to make sure the o-ring is in good
condition.
14. Install the new oil filter. After the filter contacts the engine surface,
turn it 1/2 turn by hand.
15. Remove the dipstick.
16. Add the recommended oil. See page 60.
17. Reinstall the dipstick.
18. Start the engine. Allow it to idle for two minutes.
19. Stop the engine.
20. Check for oil leaks.
21. Remove the dipstick and check the oil level. Add oil as needed.
Maintain the oil level in the safe range. Do not overfill.
22. Reinstall the dipstick.
23. Discard used oil and filter properly.
Safe
Add Oil
Safe Range
{
64
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
To r q u e
Drain Plug
To r q u e
Transmission
2x4
Premium AGL Synthetic
Gearcase Lubricant
15.2 oz.
(450 ml)
15 ft. lbs.
(20 Nm)
15 ft. lbs.
(20 Nm)
Transmission
4x4
Premium AGL Synthetic
Gearcase Lubricant
20.3 oz.
(600 ml)
15 ft. lbs.
(20 Nm)
15 ft. lbs.
(20 Nm)
Drain Plug
Fill Plug
65
MAINTENANCE
Transmission Oil
Oil Check
1. Position the vehicle on a level
surface.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Remove the fill plug.
Use a 15 mm wrench.
5. Check the oil level.
6. Add oil as needed. Do
not overfill.
7. Reinstall the fill plug.
Torque to specification.
See page 64 for recom-
mendations.
66
MAINTENANCE
Transmission Oil
Oil Change
1. Position the vehicle on a level
surface.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Remove the fill plug.
Use a 15 mm wrench.
5. Place a drain pan under
the gearcase.
6. Remove the drain plug.
Use a 15 mm wrench.
7. Allow the oil to drain
completely.
8. Clean and reinstall the 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.
12. Dispose of used oil properly.
67
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Always check and change the
demand drive fluid at the inter-
vals outlined in the Periodic
Maintenance Chart beginning
on page 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 Recommendations
Gearcase Lubricant Capacity Fill Plug
To r q u e
Drain Plug
To r q u e
Demand Drive
Unit
Premium Demand Drive
Hub Fluid
5 oz.
(148 ml)
8-10 ft. lbs.
(11-13 Nm)
8-10 ft. lbs.
(11-13 Nm)
Drain Plug
Fill
Plug
Fill
Level
68
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Check
1. Position the vehicle on a level
surface.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Remove the fill plug. Use
an 8 mm Allen wrench.
5. Check the oil level.
6. Add the recommended oil
as needed to bring the level
to the bottom of the fill
hole threads.
7. Reinstall the fill plug.
Torque to specification.
See page 67.
69
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Change
1. Position the vehicle on a level
surface.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Remove the fill plug. Use an 8
mm Allen wrench.
5. Place a drain pan under the
gearcase.
6. Remove the drain plug. Use an 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.
70
MAINTENANCE
Brake Fluid
Check brake fluid levels for both brake systems before each ride.
Always maintain brake fluid at the recommended level. Do not overfill.
If the fluid level is low add DOT 4 brake fluid only. See page 105 for the
part numbers of Polaris products.
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.
WARNING
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 recom-
mended level. Do not overfill.
WARNING
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.
71
MAINTENANCE
Brake Fluid
Hand Brake
The master cylinder is located
on the left handlebar. Main-
tain the fluid level 1/4" (6.3
mm) below the top edge of the
master cylinder. Do not over-
fill.
1. Position the vehicle on a
level surface. Make sure
the handlebars are
straight.
2. View the fluid level
through the indicator win-
dow (eye) on the top of
the master cylinder.
NOTE: The eye will appear
dark when the fluid
level is full. When fluid
is low, the eye will be
clear.
3. 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.
Master Cylinder
Indicator
Window
Minimum
Maximum
Full
Low
72
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
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 fric-
tion material is worn to .03" (.8
mm).
5. Check the security and surface
condition of the disc.
.03" (.8 mm)
73
MAINTENANCE
Toe Alignment
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 on a
level surface.
2. Place the handlebars in a
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.
NOTE: 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 mea-
surement 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.
NOTE: If you discover improper alignment, see your Polaris dealer for service.
WARNING
Do not attempt to adjust alignment. All steering adjustments should be per-
formed by an authorized Polaris dealer.
String
Stand
2
1
74
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.
Screws
Rivets
Rivets
75
MAINTENANCE
Tires
Refer to the specifications section beginning on page 110 for recom-
mended tire type, size and pressure.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical com-
ponent operations. All service must be performed by your authorized
Polaris dealer.
WARNING
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.
Maintain proper tire pressure as described on the decal on your vehicle and
in the owner's manual.
Always use original equipment size and type when replacing tires.
Make sure the wheels are installed properly.
Always replace tires when the tread depth measures 1/8" (3 mm) or less.
1/8" (3 mm)
76
MAINTENANCE
Tires
Wheel Removal
1. Position the vehicle on a level
surface.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Loosen the wheel nuts slightly.
5. Place a suitable stand under the
footrest frame to raise the wheel
slightly off the ground.
6. Remove the wheel nuts.
7. Remove the wheel.
77
MAINTENANCE
Tires
Wheel Installation
1. Place the wheel on the wheel
hub with the valve stem
toward the outside and the
rotation arrows on the tire
pointing toward forward
rotation.
2. Install the wheel nuts finger
tight.
3. Lower the vehicle to the ground.
4. Torque the wheel nuts to
specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loos-
ened for service.
WARNING
Improperly installed wheels can adversely affect tire wear and vehicle han-
dling, 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.
Nut Type Nut Torque
Lug Nut 90 ft. lbs. (122 Nm)
2-Piece Flange Nut 27 ft. lbs. (37 Nm)
90 ft. lbs.
(122 Nm)
27 ft. lbs.
(37 Nm)
CAST ALUMINUM STEEL
78
MAINTENANCE
Air Filter/Breather Filter
1. Position the vehicle on a level
surface.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Remove the seat.
5. Release the air box
cover clips, and
remove the air box
cover.
6. Remove the air filter.
7. Remove the sleeve
from the filter.
8. 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.
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.
CAUTION
Operation of your vehicle without a breather filter can cause engine damage.
Always reinstall the breather filter after removing it for service.
Air Filter
Clips
Breather
Filter
Sleeve
79
MAINTENANCE
Lights
Headlight Beam Adjustment
The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.
1. Position the vehicle on a level surface with the headlight approxi-
mately 25 ft. (7.6 m) from a wall.
2. Place the transmission in neutral.
3. Lock the parking brake.
4. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
NOTE: 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.
7. Loosen the phillips screw at the rear of the headlamp.
8. Adjust the beam.
9. Tighten the screw.
25 ft.
(7.6 m)
2" (5 cm)
80
MAINTENANCE
Lights
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.
Headlamp Replacement
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
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.
WARNING
Poor lighting while driving can result in severe injury or death. Headlight and
taillight lenses become dirty during normal operation. Wash the headlights
frequently to maintain lighting quality.
Hot components can cause serious burns to skin. Allow lamps to cool before
servicing.
Harness
Screw
Lamp
Cover
81
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.
4. Remove the drain screw on the
bottom of the recoil housing.
5. Reinstall the drain screw.
NOTE: Do not open the crankcase drain
unless the engine has ingested
water. On 4-cycle engines, some
engine oil will be lost if the crank-
case drain is opened.
82
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
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.
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 83.
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.
CAUTION
Using non-recommended spark plugs can result in serious engine damage.
Always use Polaris-recommended spark plugs.
Plug Condition Torque Specification
New Spark Plug 9-11 ft. lbs. (12-15 Nm)
Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)
WARNING
A hot exhaust system and engine can cause serious burns. Wear protective
gloves when removing a spark plug for inspection.
Spark Plug
83
MAINTENANCE
Spark Plugs
Spark Plug Inspection
4. Inspect the electrodes for wear
and carbon buildup. Replace
worn or fouled plugs. Verify that
the gap is at specification before
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.
NOTE: The tip should not be flaky and white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect
carburetion 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.
84
MAINTENANCE
Vehicle Immersion
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.
2. Turn the fuel valve off.
3. Check the air box. If water is
present, dry the air box and replace
the filter with a new filter.
4. Remove the 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 87 for drying out the PVT.
CAUTION
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.
Drain
Screw
85
MAINTENANCE
Spark Arrestor
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 brake.
4. Remove the arrestor
clean-out plug from the
bottom of the muffler.
5. Start the engine.
6. Quickly squeeze and release the throttle lever several times to purge
carbon from the system.
7. If carbon 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. If particles 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. Place the transmission in neutral. Lock the parking brake. 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.
WARNING
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 purg-
ing. Never run the engine in an enclosed area. Exhaust contains poisonous
carbon monoxide gas. Never go under the vehicle while it's inclined.
Exhaust
Outlet
Clean-Out Plug
86
MAINTENANCE
PVT System
WARNING
Failure to comply with the instructions in this warning can result in severe
injury or death.
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a 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 fol-
lowing responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. See your dealer
as outlined in the owner's manual.
• 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.
87
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 screw-
driver, or the spark plug wrench.
3. Allow the water to drain com-
pletely. Reinstall the drain plug.
4. Start the engine. Place the trans-
mission in neutral.
5. Apply varying throttle for 10-15
seconds to expel the moisture
and air-dry the belt and clutches.
NOTE: Do not hold the throttle wide
open for more than 10 seconds.
6. Allow the engine RPM to settle
to idle speed, then shift the trans-
mission 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.
PVT Drain
Plug
88
MAINTENANCE
Battery
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.
Conventional 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.
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. 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.
89
MAINTENANCE
Battery
Battery Removal
1. Place the transmission in
gear.
2. Lock the parking brake.
3. Open the front cover.
4. Disconnect the battery hold-
down strap.
5. On conventional batteries,
remove the battery vent
tube.
6. Disconnect the black (nega-
tive) battery cable first.
7. Disconnect the red (posi-
tive) battery cable last.
8. Lift the battery out of the
vehicle. Be careful not to tip
a conventional battery sideways, which could spill electrolyte.
WARNING
Improperly connecting or disconnecting battery cables can result in an explo-
sion 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.
CAUTION
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.
90
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 92 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).
NOTE: The vent tube must be free of obstructions and securely installed.
Route the tube away from the frame and vehicle body to prevent con-
tact with electrolyte.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Secure the battery hold-down strap.
8. Verify that cables are properly routed.
NOTE: Cables should be safely tucked away at the front and rear of the bat-
tery.
WARNING
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.
91
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.
NOTE: 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
the battery fluid level often.
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
Mark
Upper
Mark
92
MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leak-
ing or spilled electrolyte during charging. See page 89.
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 90. 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. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
NOTE: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger,
use the following guidelines for recharging.
WARNING
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very
warm to the touch. Allow it to cool before resuming charging.
93
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
NOTE: Always verify battery condition before and 1-2 hours after the end of
charging.
State of
Charge
Voltage Action
Charge Time
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at 3
mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
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
94
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.
The best and safest way to clean your Polaris vehicle is with a garden
hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• 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.
CAUTION
High water pressure may damage components. Polaris recommends wash-
ing 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.
95
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 decals. Avoid directing the water stream at the follow-
ing items:
• Wheel bearings
• Transmission seals
•Brakes
• Cab and body panels
• Labels and decals
NOTE: If warning and safety labels are damaged, contact your Polaris dealer
for free replacement.
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
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• 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.
96
MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion, pre-
serve wheel life and ensure a "like new" appearance for many years.
NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas)
are more 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 (#0000-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.
97
MAINTENANCE
Cleaning and Storage
Storage Tips
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 94.
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.
NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and
removes carbon deposits from pistons, rings, valves and exhaust sys-
tems.
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 81.
CAUTION
Starting the engine during the storage period will disturb the protective film
created by fogging and damage could occur. Never start the engine during
the storage period.
98
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.
• Demand drive unit (front gearcase)
• Transmission
• 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 Clean. See page 97.
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.
99
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 91-92 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the vehicle with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine Polaris cover.
NOTE: Do not use plastic or coated materials. They do not allow enough ven-
tilation to prevent condensation, and may promote corrosion and oxi-
dation.
Accessories
Auxiliary power outlets provide 12-volt power for operating accesso-
ries. Accessory outlets are available for all models. Polaris 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.
100
MAINTENANCE
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Turn the fuel valve off.
5. Secure the fuel cap, oil cap and seat.
6. Remove the key to prevent loss during transporting.
7. 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.
101
ADJUSTMENTS
Camber and Caster
The camber and caster are non-adjustable.
Spring Adjustments
The front and rear shock absorber springs are adjustable. Rotate the
adjuster either clockwise or counterclockwise to increase or decrease
spring tension. Always adjust both sides equally.
NOTE: Accessory springs are available through your Polaris dealer.
Rear
Adjuster
Front
Adjuster
102
ADJUSTMENTS
Handlebars
The handlebars can be adjusted for rider preference.
1. Loosen the four handlebar bolts.
2. Adjust the handlebar to the
desired height.
NOTE: 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.
3. Torque the front two bolts to
10-12 ft. lbs. (14-17 Nm), then
torque the rear two bolts. A gap
of up to 1/8" (3 mm) will
remain at the rear bolts.
WARNING
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.
Handlebar
Bolts
103
ADJUSTMENTS
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, available from your Polaris dealer, are required for
operation above 6,000 feet and temperatures below +40 degrees F. (4
degrees C.)
NOTE: 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
104
ADJUSTMENTS
Throttle Cable Freeplay
Adjust throttle cable freeplay at the handlebar.
1. Locate the throttle cable
adjuster at the handlebar.
2. Squeeze the end of the rub-
ber boot and slide it far
enough to expose the end of
the inline cable adjuster.
3. Loosen the adjuster lock nut.
4. 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.
NOTE: While adjusting freeplay,
be sure to flip the throttle
lever back and forth.
5. Tighten the lock nut.
6. Squeeze the end of the rub-
ber boot and slide it over the
cable adjuster to its original
position.
Lock Nut
Adjuster
Boot
105
POLARIS PRODUCTS
Part
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 oz.)
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 Premium U-Joint Lube (3 oz.)
2871551 Premium U-Joint Lube (14 oz.)
2871329
Dielectric Grease (Nyogel
TM
)
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 DOT4 Brake Fluid (12 oz.)
2871956
Loctite
TM
565 Thread Sealant
2859044
Polaris Battery Tender
TM
Charger
106
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause Solution
Driving onto a pickup or
tall trailer in high range
Use low range (if equipped).
Starting out going up a
steep incline
Use low range (if equipped) or turn around using the K-
turn (see page 46).
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 Shift the transmission to low range (if equipped). Care-
fully use fast, aggressive throttle application to engage
clutch. WARNING: Excessive throttle may cause loss of
control and vehicle overturn.
Climbing over large
objects from a stopped
position
Belt slippage from water
or snow ingestion into the
PVT system
Dry out the PVT. See page 87. 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.
107
TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Blown fuse Replace fuse
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel 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
Old 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 Inspect plugs, verify stop switch is on
Overuse of choke 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
Possible Cause Solution
Weak spark from spark plug 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
Incorrectly installed spark plug wires See your dealer
Incorrect ignition timing See your dealer
Mechanical failure See your dealer
108
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
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
Possible Cause Solution
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 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
Possible Rich Fuel Cause Solution
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
109
TROUBLESHOOTING
Engine Stops or Loses Power
Engine Overheating
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Kinked or plugged fuel vent line Inspect and replace
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
Loose 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 See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Possible Cause Solution
Towing/dragging heavy loads Install the accessory oil cooler if this
vehicle will be used for towing heavy
loads, dragging ground surfaces or per-
forming similar activities.
Operating in excessive heat Install the accessory oil cooler if this
vehicle is normally operated when air
temperature is above 100° F. (38° C).
110
SPECIFICATIONS
* Based on EU Directive 76/432/EC
Hawkeye 2X4
Gross Vehicle Weight 930 lbs. (422 kg)
Dry Weight 525 lbs. (238 kg)
Fuel Capacity 4.5 gal. (17 l)
Engine Oil Capacity 2 qts. (1.9 l)
Transmission Oil 15.2 oz. (450 ml)
Demand Drive Fluid 5 oz. (148 ml)
Front Rack Capacity 70 lbs. (32 kg)
Rear Rack Capacity 100 lbs. (45 kg)
Hitch Tongue Weight Capacity 75 lbs. (34 kg) (Rear rack capacity and tongue
weight not to exceed 100 lbs./45 kg)
Hitch Towing Rating 750 lbs. (340.2 kg)
Unbraked Trailer Towing
Capacity*
1213 lbs. (550 kg)
Overall Length 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 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
111
SPECIFICATIONS
Jetting Chart
Clutching Chart
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) Accessory
Windshield Accessory
Speedometer/Odometer/
Tripmeter/Hourmeter
Standard
Fuel Gauge Standard
Tool Kit Standard
ALTITUDE
Meters (Feet)
AMBIENT TEMPERATURE
Below 40° F
(Below 5° C)
40°F and above
(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
Altitude
Meters (Feet)
Roller
Weight
Number of Rollers Driven Clutch
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
(Remove two opposite
rollers to maintain
clutch balance)
7043228
112
SPECIFICATIONS
* Based on EU Directive 76/432/EC
Hawkeye 4X4
Gross Vehicle Weight 930 lbs. (422 kg)
Dry Weight 550 lbs. (250 kg)
Fuel Capacity 4.5 gal. (17 l)
Engine Oil Capacity 2 qts. (1.9 l)
Transmission Oil 20.3 oz. (600 ml)
Demand Drive Fluid 5 oz. (148 ml)
Front Rack Capacity 70 lbs. (32 kg)
Rear Rack Capacity 100 lbs. (45 kg)
Hitch Tongue Weight Capacity 75 lbs. (34 kg) (Rear rack capacity and tongue
weight not to exceed 100 lbs./45 kg)
Hitch Towing Rating 750 lbs. (340.2 kg)
Unbraked Trailer Towing
Capacity*
1213 lbs. (550 kg)
Overall Length 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)
113
SPECIFICATIONS
Jetting Chart
Clutching Chart
Hawkeye 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
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/
Tripmeter/Hourmeter
Standard
Fuel Gauge Standard
Tool Kit Standard
ALTITUDE
Meters (Feet)
AMBIENT TEMPERATURE
Below 40° F
(Below 5° C)
40°F and above
(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
Altitude
Meters (Feet)
Roller
Weight
Number of Rollers Driven Clutch
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
(Remove two opposite
rollers to maintain
clutch balance)
7043228
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 Quadricycle 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. THE PURCHASER MUST COMPLETE A
QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN
ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE. No verification
of registration will be sent to the purchaser as the copy of the Warranty Registration
Form will be the warranty entitlement. If you have not signed the original registration
and received the "customer copy", please contact your dealer immediately. NO WAR-
RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS
REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your vehicle is very important in ensuring trou-
ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
115
WARRANTY
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 Quadricycle
that has been altered structurally, modified, neglected, improperly maintained, used for
racing, or used for purposes other than for which it was manufactured, or for any dam-
ages 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.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the Quadricycle. The exclusive remedy for breach of this war-
ranty shall be, at Polaris' exclusive option, repair or replacement of any defective materi-
als, 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
DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-
RANTY 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.
116
WARRANTY
HOW TO OBTAIN WARRANTY SERVICE
If your Quadricycle requires warranty service, you must take it to a Polaris dealer autho-
rized to repair Polaris Quadricycles. When requesting warranty service you must present
your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS-
PORTATION 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
120
INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . 99
Age Restrictions. . . . . . . . . . . . . . . . . 7
Air Filter . . . . . . . . . . . . . . . . . . . . . 78
All Wheel Drive Switch. . . . . . . . . . 21
All Wheel Drive System . . . . . . . . . 29
AWD Switch . . . . . . . . . . . . . . . . . . 29
AWD System . . . . . . . . . . . . . . . . . . 29
B
Battery . . . . . . . . . . . . . . . . . . . . 88-93
Charging (Conventional) . . . . . 92
Charging (Sealed) . . . . . . . . 92-93
Conventional . . . . . . . . . . . . . . 88
Fluid (Conventional) . . . . . . . . 91
Installation . . . . . . . . . . . . . . . . 90
Removal. . . . . . . . . . . . . . . . . . 89
Storage . . . . . . . . . . . . . . . . . . . 91
Boots . . . . . . . . . . . . . . . . . . . . . . . . 19
Brake Fluid . . . . . . . . . . . . . . . . . 70-71
Brake Inspections. . . . . . . . . . . . . . . 72
Brake Lever . . . . . . . . . . . . . . . . . . . 23
Brake, Foot . . . . . . . . . . . . . . . . . . . 25
Brake, Parking . . . . . . . . . . . . . . . . . 24
Brakelight . . . . . . . . . . . . . . . . . . . . 80
Brakes . . . . . . . . . . . . . . . . . . . . . . . 72
Break-In Period . . . . . . . . . . . . . . 33-34
Breather Filter . . . . . . . . . . . . . . . . . 78
C
Camber Adjustment . . . . . . . . . . . . 101
Carburetor . . . . . . . . . . . . . . . . . . . 103
Carburetor Adjustment . . . . . . . . . 103
Cargo . . . . . . . . . . . . . . . . . . . . . . 38-39
Caster Adjustment . . . . . . . . . . . . . 101
Choke. . . . . . . . . . . . . . . . . . . . . . . . 26
Chrome Wheel Care . . . . . . . . . . . . 96
Cleaning and Storage. . . . . . . . . . 94-99
Clothing . . . . . . . . . . . . . . . . . . . . . . 19
Clutching Chart, 2X4. . . . . . . . . . . 111
Clutching Chart, 4X4. . . . . . . . . . . 113
Cold Weather Operation . . . . . . . . . 37
Corrosion Removal, Chrome. . . . . . 96
D
Demand Drive Fluid . . . . . . . . . . 67-69
Drive Belt Wear/Burn . . . . . . . . . . . 106
Drivetrain Break-In . . . . . . . . . . . . . . 34
Driving Downhill. . . . . . . . . . . . . . . . 45
Driving in Reverse. . . . . . . . . . . . . . . 51
Driving on a Sidehill . . . . . . . . . . . . . 44
Driving on Slippery Surfaces . . . . . . 42
Driving Over Obstacles . . . . . . . . . . . 50
Driving Procedures . . . . . . . . . . . . . . 40
Driving Safely . . . . . . . . . . . . . . . 40-52
Driving Through Water . . . . . . . . 48-49
Driving Uphill . . . . . . . . . . . . . . . . . . 43
E
Electromagnetic Interference. . . . . . . 53
Engaging AWD . . . . . . . . . . . . . . . . . 29
Engine Break-In. . . . . . . . . . . . . . . . . 34
Engine Fogging . . . . . . . . . . . . . . . . . 98
Engine Idle RPM Adjustment . . . . . 103
Engine Oil . . . . . . . . . . . . . . . . . . 60-61
Equipment Modifications . . . . . . . . . . 7
Exhaust Emission Control System . . 53
Eye Protection . . . . . . . . . . . . . . . . . . 19
F
Fluid
Brake . . . . . . . . . . . . . . . . . . 70-71
Demand Drive . . . . . . . . . . . 67-69
Transmission . . . . . . . . . . . . 64-66
Foot Brake, Auxiliary . . . . . . . . . . . . 25
Footwell Removal . . . . . . . . . . . . . . . 74
Front Gearcase. . . . . . . . . . . . . . . 67-69
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 26
Fuel Safety. . . . . . . . . . . . . . . . . . . . . 32
Fuel Tank Cap . . . . . . . . . . . . . . . . . . 26
Fuel Valve . . . . . . . . . . . . . . . . . . . . . 26
G
Gear Selector . . . . . . . . . . . . . . . . . . . 27
Gloves . . . . . . . . . . . . . . . . . . . . . . . . 19
121
INDEX
H
Handlebar Adjustment . . . . . . . . . . 102
Hauling Cargo. . . . . . . . . . . . . . . 38-39
Headlamp Replacement . . . . . . . . . . 80
Headlight Beam Adjustment. . . . . . . 79
Headlight Switch. . . . . . . . . . . . . . . . 21
Helmet. . . . . . . . . . . . . . . . . . . . . . . . 18
I
Idle RPM Adjustment . . . . . . . . . . . 103
Immersion . . . . . . . . . . . . . . . . . . . . . 84
Instrument Cluster. . . . . . . . . . . . 30-31
J
Jetting Chart, 2X4. . . . . . . . . . . . . . 111
Jetting Chart, 4X4. . . . . . . . . . . . . . 113
K
Key Switch . . . . . . . . . . . . . . . . . . . . 21
K-Turn . . . . . . . . . . . . . . . . . . . . 46-47
L
Lights . . . . . . . . . . . . . . . . . . . . . 79-80
Headlamp Replacement . . . . . . 80
Headlight Beam Adjustment. . . 79
Taillight/Brakelight. . . . . . . . . . 80
Lubrication Guide. . . . . . . . . . . . . . . 59
M
Maintenance Chart . . . . . . . . . . . 54-58
Mode Switch. . . . . . . . . . . . . . . . . . . 20
Modifications . . . . . . . . . . . . . . . . . . . 7
N
Noise Emission Control System . . . . 53
O
Oil
Engine . . . . . . . . . . . . . . . . . 60-61
Transmission. . . . . . . . . . . . 64-66
Oil and Filter Change . . . . . . . . . 62-63
Oil Level, Engine . . . . . . . . . . . . . . . 61
Oil Recommendations. . . . . . . . . . . . 60
Operator Safety . . . . . . . . . . . . . . . 6-13
Override Switch . . . . . . . . . . . . . . . . 20
P
Parking Brake . . . . . . . . . . . . . . . . . . 24
Parking on an Incline . . . . . . . . . . . . 52
Periodic Maintenance Chart . . . . 54-58
Polaris Product List. . . . . . . . . . . . . 105
Polishing the Vehicle . . . . . . . . . . . . 95
Pre-Ride Checklist . . . . . . . . . . . . . . 35
PVT Break-In . . . . . . . . . . . . . . . . . . 34
PVT Drying . . . . . . . . . . . . . . . . . . . 87
PVT System . . . . . . . . . . . . . . . . 86-87
R
Recoil Housing . . . . . . . . . . . . . . . . . 81
Recoil Starter . . . . . . . . . . . . . . . . . . 28
Reverse Operation . . . . . . . . . . . . . . 51
Reverse Override Switch . . . . . . . . . 20
Rider Information Center . . . . . . . . . 31
Riding Gear. . . . . . . . . . . . . . . . . 18-19
S
Safety Decals . . . . . . . . . . . . . . . 14-17
"No Passenger" Warning . . . . . 16
Age 16 Warning . . . . . . . . . . . . 16
All Wheel Drive Switch . . . . . . 17
Clutch Cover Warning . . . . . . . 17
Discretionary Warning . . . . . . . 15
General Warning. . . . . . . . . . . . 14
Hitch Capacity Label . . . . . . . . 17
Rack Warning, Front and Rear . 17
Reverse Override Warning . . . . 17
Tire Pressure/Load Warning. . . 15
Safety Training . . . . . . . . . . . . . . . . . . 7
Severe Use . . . . . . . . . . . . . . . . . . . . 54
Side Panel Removal . . . . . . . . . . . . . 74
Sidehilling. . . . . . . . . . . . . . . . . . . . . 44
Signal Words . . . . . . . . . . . . . . . . . . . 6
Spark Arrestor. . . . . . . . . . . . . . . . . . 85
Spark Plugs . . . . . . . . . . . . . . . . . 82-83
Spring Adjustments . . . . . . . . . . . . 101
Starting the Engine . . . . . . . . . . . 36-37
Steering Assembly . . . . . . . . . . . . . . 74
Storage . . . . . . . . . . . . . . . . . . . . 94-99
122
INDEX
S
Switches
AWD Switch . . . . . . . . . . . 21, 29
Engine Stop Switch . . . . . . . . . 21
Headlight Switch . . . . . . . . . . . 21
Main Key Switch . . . . . . . . . . . 21
Mode/Reverse Override Switch 20
T
Taillight . . . . . . . . . . . . . . . . . . . . . . 80
Throttle Cable Freeplay . . . . . . . . . 104
Throttle Lever . . . . . . . . . . . . . . . . . 22
Tire Tread Depth . . . . . . . . . . . . . . . 75
Tires . . . . . . . . . . . . . . . . . . . . . . 75-77
Front Wheel Hub Tightening. . 75
Tread Depth . . . . . . . . . . . . . . . 75
Wheel Installation . . . . . . . . . . 77
Wheel Nut Torque . . . . . . . . . . 77
Wheel Removal . . . . . . . . . . . . 76
Toe Alignment . . . . . . . . . . . . . . . . . 73
Towing Loads . . . . . . . . . . . . . . . . . 38
Training, Safety . . . . . . . . . . . . . . . . . 7
Transmission Oil . . . . . . . . . . . . . 64-66
Transporting the Vehicle . . . . . . . . 100
Turning Around on a Hill . . . . . . 46-47
Turning the Vehicle . . . . . . . . . . . . . 41
V
Vehicle Identification Numbers. . . . . . 5
Vehicle Immersion . . . . . . . . . . . . . . 84
W
Warning Symbols . . . . . . . . . . . . . . . . 6
Washing the Vehicle . . . . . . . . . . 94-95
Wheel Hub Tightening . . . . . . . . . . . 75
Wheel Installation . . . . . . . . . . . . . . . 77
Wheel Nut Torque Specifications . . . 77
Wheel Removal . . . . . . . . . . . . . . . . . 76
