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2007 Hawkeye 2x4 and 4x4 Owner`s Manual

Contents

1. 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 Standard Tripmeter Hourmeter Fuel Gauge Standard Tool Kit Standard Jetting Chart ALTITUDE AMBIENT TEMPERATURE Meters Feet Below 40 F 40 F and above Below 5 C 5 C and above 0 900 0 3000 145 140 900 1800 3000 6000 Same main jet Remove 2 air box plugs 1800 2700 6000 9000 Same main jet Remove 4 air box plugs Above 2700 Above 9000 Same main jet Remove 6 air box plugs Above 3000 Above 10000 Same main jet Remove 6 air box plugs Move jet needle clip to position 2 Clutching Chart Altitude Roller Number of Rollers Driven Clutch Meters Feet Weight Spring 0 1500 0 5000 13 g 5412988 8 7043228 1500 3000 5000 10000 10
2. TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Engine Runs Irregularly Stalls or Misfires 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 Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting Possible Rich Fuel Cause Overuse of choke See your dealer Solution Inspect clea
3. 42 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 ATV is in two wheel drive at all times When the switch is on AWD the ATV is in all wheel i AWD drive and the AWD indicator light Switch in the instrument cluster will be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 34 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
4. AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ij Vy r gt Part No 9920787 Rev A We Ee BEN THE USA AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory motorcycles We
5. 43 Engine Break In 48 Engine Fogging 112 Engine Idle RPM Adjustment 117 Engine Oil 74 75 Equipment Modifications 18 Exhaust Emission Control System 67 Eye Protection 11 F Fluid Brake ta facie vs 84 85 Demand Drive 81 83 Foot Brake Auxiliary 39 Footwell Removal 88 Front Gearcase 81 83 Fuel Filter 3c0ccc seaese ean sis 40 Fuel Safety 00 46 Fuel Tank Cap 0 40 Fuel Valvessicy cae cosy as See s 40 G Gear Selecto essar arvu donesia 41 GIVES lerares sey cbse puaga 11 H Handlebar Adjustment 116 Hauling Cargo 52 53 Headlamp Replacement 94 Headlight Beam Adjustment 93 Headlight Switch 35 Helmet anaa A E eth 10 l Idle RPM Adjustment 117 Immersion 000 98 Instrument Cluster 44 45 J Jetting Chart 2X4 125 Jetting Chart 4X4 127 K Key Switch 0 35 KEP UIs ah ease icad a tas 60 61 L Lights Headlamp Replacement 94 Headlight Beam Adjustment 93 Taillight Brakelight 94 Lubrication Guide 73 M Maintenance Chart 68 72 Mode Switch 0 34 Modifications 0 18 N Noise Emission Control System 67 O Oil Engine 2 74 75 Trans
6. Grease fittings 3 pumps maxi mum every 500 miles 800 km before long periods of storage or after pressure washing or submerging Front Prop Shaft Yoke Bearing Carrier O Transmission Upper Pivot Point 73 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Performance Synthetic 4 Stroke PS 4 OW 50 oil for this engine PS 4 is a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication per formance and protection Oil may need to be changed more frequently if Polaris oil is not used Always use 0W 50 oil Follow the manufacturer s recommendations for ambient temperature operation 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 Oil Specifications Lubricant Capacity Drain Plug Torque Performance Synthetic 2 ats 1 9 I 14 ft Ibs 19 Nm 4 Stroke PS 4 OW 50 74 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the ATV 1 2 3 Position the vehicle on a level surface Place the transmission in neutral Lock the parking brake Start the engine Allow it to idle for 30 seconds Dipstick Stop the engine Remove the dipstick Wipe it dry with a clean L
7. 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 r Idle Adjuster 117 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 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 118 a Boot Lock Nut Adjuster POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2874865 Performance Synthetic 4 Stroke PS 4 OW 50 Oil qt 2874866 Performance Synthetic 4 Stroke PS 4 OW 50 Oil gal Gearcase T
8. 50 51 Steering Assembly 88 Storage vis see Scale voy OK 108 113 Switches AWD Switch 35 43 Engine Stop Switch 35 Headlight Switch 35 Main Key Switch 35 Mode Switch 34 Reverse Override Switch 34 137 INDEX T Taillight 02 000 94 Throttle Cable Freeplay 118 Throttle Lever 36 Tire Tread Depth 89 Tires Front Wheel Hub Tightening 89 Tread Depth 89 Wheel Installation 91 Wheel Nut Torque 91 Wheel Removal 90 Toe Alignment 87 Towing Loads 52 Trainin es euet ostari eee aed pat 2 13 Transmission Oil 78 80 Transporting the Vehicle 114 Turning Around ona Hill 60 61 Turning the Vehicle Bp 138 V Vehicle Identification Numbers 5 Vehicle Immersion 98 Ww Warning Symbols 14 Washing the Vehicle 108 109 Wheel Hub Tightening 89 Wheel Installation 91 Wheel Nut Torque Specifications 91 Wheel Removal 90
9. 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 Sanne ea NS S Engine Serial Number Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions of the decals on the ATV carefully If any of the decals depicted in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV 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 e without proper training or instruction e at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough ter rain and i
10. 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 A 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 64 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse PETENS 1 Always check for obstacles or people a 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 A 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 NOTE Your Polaris ATV 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 CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engin
11. Disconnect the black nega tive battery cable first 7 Disconnect the red posi tive battery cable last 8 Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte 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 103 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 106 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 A 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 4 On conventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Conne
12. front gearcase Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean See page 111 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 112 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 68 Battery Storage See pages 105 106 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV 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 conden
13. 27 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost Keep your weight uphill Apply the brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 60 28 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper pro cedures as outlined in the owner s manual A WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain tra
14. Do not operate at full throttle or high speeds during the first three hours of use 47 OPERATION Break In Period Engine and Drivetrain Break in 1 2 3 Fill the fuel tank with gasoline See page 40 Check the oil level on the dipstick See page 75 Add oil if neces sary to maintain the level between the safe and add marks Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling Vary the throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 49 Pull only light loads During the break in period change both the oil and the filter at 20 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 48 Pre Ride Checklist OPERATION A WARNING proper operating condition 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 Item Remarks Page Brake system lever travel E
15. Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt General 50H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Carburetor float 50H 6M 500 800 Drain bowl periodically and bowl prior to storage E Throttle Cable 50H 6M 500 800 Inspect adjust lubricate E ETC Switch replace if necessary E Choke cable 50H 6M 500 800 Inspect adjust lubricate E replace if necessary E Carburetor air 50H 6M 500 800 Inspect duct for proper seal intake ducts flange ing air leaks Drive belt 50H 6M 500 800 Inspect adjust replace as needed gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at 20 hours gt Oil filter change 100 H 6M 1000 1600 Replace with oil change gt Oil tank vent hose 100 H 6M 1000 1600 Inspect routing condition if equipped E Valve clearance 100 H 12M 1000 1600 Inspect adjust E Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100H 12M 1000 1600 Inspect pipe Spark plug 100 H 12M 1000 1600 Inspect replace as needed p Ignition Timing 100 H 12M 1000 1600 Inspect gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc 71 MAIN
16. Ride vake anustnente as need 7 z ed See Pre Ride Checklist gt Front suspension Pre Ride on page 49 gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride P Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Headlamp tail Daily Check operation apply lamp dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element Recoil housing Weekly Drain water as needed if applicable check often if operating in wet conditions gt Brake pad wear 10H Monthly 100 160 Inspect periodically a Battery 20H Monthly 200 320 Check terminals clean test gt Front gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped gt Transmission oil 25H Monthly 250 400 Inspect level change yearly gt Engine breather 25H Monthly 250 400 Inspect clean if needed E filter if equipped gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service Have an authorized Polaris dealer perform these services 70 Periodic Maintenance Chart MAINTENANCE Item
17. 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 maximum tongue weight capacity can 6 3 4 17 cm result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 6 3 4 17 cm Never install automotive accessories on your Polaris ATV Always install Polaris approved or equivalent accessories designed for ATV use p l ea ce oars 52 OPERATION Hauling Cargo A 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 P
18. a sharp drop or another vehicle or person could be on the other side of the hill 26 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 59 Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible A WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s man ual See page 60 Use extra caution when turn ing on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV
19. alignment and adjust ment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out l NOTE Place the handlebars in a straight ahead position Place stands in front of the vehicle per pendicular to the rear tires Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle Measure the distance from the string to the rim at the front and rear of the front rim Rear measurement o String Rear of Front Rim Front of a Front Rim Stands should be 1 16 to 1 8 2 3 mm more than the front measurement If you discover improper alignment see your Polaris dealer for service 87 MAINTENANCE Steering Assembly The steering assembly of the ATV 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
20. at rest 43 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel The instrument cluster measures distance in miles as Loon well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph ml ee Refer to page 34 for additional information OLOKO CAUTION High water pressure may damage ATV components Wash the ATV 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 Miles Kilometers Toggle The display in the tripmeter odometer and speedometer can be changed to display either kilometers or miles 1 To change modes press and release the mode button see page 31 as often as needed to reach the odometer mode 2 Inthe odometer mode press and hold the mode button until the let ters flash then release the button 3 Press and release the button one more time When the display stops flashing the mode has been set 44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The
21. believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2006 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 t
22. cloth ues Reinstall the dipstick completely Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Safe Range Add Oil Safe Reinstall the dipstick 75 MAINTENANCE Oil and Filter Change A CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 68 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Lock the parking brake 4 Start the engine Allow it to idle for two to three minutes Stop the engine Fea 5 Clean the area around the drain plug O 6 Place a drain pan under the vehicle Oy 7 Remove the drain plug Use a 6 mm K g5 Allen wrench 8 Drain the oil 9 Reinstall the drain plug with a new sealing washer gt NOTE The sealing surfaces on the drain plug and Q crankcase should be clean and free of Co burrs nicks or scratches 10 Torque to specification See page 74 76 MAINTENANCE Oil and Filter Change 11 12 13 14 15 16 17 18 19 20 21 22 23 Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it Clean the filter sealing area on the engine Lubric
23. 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 SAFETY Safety Decals and Locations Age 16 Warning Rack Warning No Passenger Warning Clutch Cover Warning No Passenger Warning WARNING NEVER ride as a passenger pene can cause a loss of control resulting in SEVERE INJURY or 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 SAFETY Safety Decals and Locations Clutch Cover Warning WARNING NO STEP e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed e Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch e Max Rack Loads Front 70 Ibs 32 kg Rear 100 Ibs 46 kg Reverse Override Warning 4X4 Models WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle
24. face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an ATV Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation 15 SAFETY Operator Safety 16 Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills Check the terrain carefully before ascending a hill Never climb hills with excessively slippery or loose surfaces Shift your weight uphill Never op
25. filter can cause engine damage Always reinstall the breather filter after removing it for service Reinstall the sleeve over the air filter Replace the filter if needed Reinstall the air filter into the air box Reinstall the air box cover and the seat MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 4 25 ft Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in neutral Lock the parking brake 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 6 Start the engine Turn the headlight switch to high beam Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Loosen the phillips screw at the rear of the headlamp Adjust the beam Tighten the screw 93 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 A WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights fr
26. g 5412986 8 7043228 3000 10000 10 g 5412986 6 i 7043228 Remove two opposite rollers to maintain clutch balance 127 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without pr
27. 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 41 FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start Handle the engine use the recoil starter Follow the starting procedures on page 50 cranking the engine with the recoil starter instead of the main key switch Recoil Starter 1 Grasp the recoil starter rope handle tightly 2 Pull slowly so you can feel the 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
28. 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 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury eee Eye Protection Long Sleeves Gloves Long Pants Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label 10 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever ri
29. 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 ATV Trip Meter The trip meter records the distance traveled by the ATV 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 45 OPERATION Fuel Safety A 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
30. the ignition key when the vehicle is not in use 33 FEATURES AND CONTROLS Switches Headlight Switch Main Key Switch Mode Reverse Engine All Wheel Drive Override Stop Switch Switch Switch A 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 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 44 34 FEATURES AND CONTROLS Switches Engine Stop Switch gt Move the stop switch either left a or right to the OFF position to wi stop the engine quickly The ss engine will not start or run when OFF RUN OFF 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 50 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
31. 7 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 8 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 6 9 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 10 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 99 MAINTENANCE PVT System A 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 e This PVT system is intended for use on Polaris products onl
32. ATV is normally operated when the air temper ature is above 100 F 38 C 123 SPECIFICATIONS Hawkeye 2X4 Gross Vehicle Weight 930 Ibs 422 kg Dry Weight 525 lbs 238 kg Fuel Capacity 4 5 gal 17 D Engine Oil Capacity 2 qts 1 9 1 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 Weight Capacity 750 Ibs 340 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 Minimum Turning Radius 8 in 20 cm 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 4HCS57 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 Fina
33. 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 A 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 46 OPERATION Break In Period The break in period for your new Polaris ATV 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 e The vehicle will be used for dragging ground surfaces or performing similar activities e The vehicle is normally operated when the air temperature is above 100 F 38 C CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components
34. HER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 129 WARRANTY 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 SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal righ
35. NING 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 1 Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation 2 Install the wheel nuts finger tight 3 Lower the vehicle to the ground 4 Torque the wheel nuts to specification Wheel Nut Torque Specifications 90 ft Ibs 122 Nm o CAST ALUMINUM Check the wheel nut torques occasionally and when they ve been loos ened for service Nut Type Nut Torque Lug Nut 90 ft Ibs 122 Nm 2 Piece Flange Nut 27 ft lbs 37 Nm 91 MAINTENANCE Air Filter Breather Filter l AYN 10 11 Position the vehicle on a level surface Place the transmission in gear Lock the parking brake Remove the seat Release the air box cover clips and remove the air box cover Remove the air filter Remove the sleeve from the filter Wash the sleeve in soapy water then rinse and let dry Remove the breather filter Wash the breather filter in soapy water then rinse and let dry Reinstall the breather filter CAUTION 12 13 14 92 Operation of your vehicle without a breather
36. OSSIBLE 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 53 OPERATION Driving Safely Driving Procedures y 20 D OIS A 54 Wear protective riding gear See page 10 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allo
37. TENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts E Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out Idle speed Adjust as needed E Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service E Have an authorized Polaris dealer perform these services 72 Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 68 Items not listed in the chart should be lubricated at the General Lubrication MAINTENANCE interval Item Lube Method Engine Oil Polaris Premium 4 Synthetic See page 74 OW 50 Brake Fluid DOT 4 Only See page 84 Transmission Oil Polaris AGL Synthetic See page 78 Gearcase Lube Front Demand Drive Unit Premium Demand Drive Hub See page 81 Front Gearcase Fluid Front Prop Shaft Yoke Control Arm front and rear Bearing Carrier Transmission upper pivot point Polaris Premium U Joint Lube
38. age 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 106 Battery MAINTENANCE Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts At least 13 hours 25 50 11 5 12 0 volts Needs charge verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 107 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 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
39. aight 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 ATV Maintain the fluid level between the minimum and maximum marks Do not overfill 85 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 84 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 gt lt 03 8 mm 86 Toe Alignment MAINTENANCE A WARNING Severe injury or death can result from improper toe
40. allow these types of products to contact the vehicle 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 e Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 108 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 e Wheel bearings e Transmission seals e Brakes e Cab and body panels e 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
41. ansmission 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 78 for recom mendations 79 MAINTENANCE Transmission Oil Oil Change 1 Position the vehicle on a level surface Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use a 15 mm wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use a 15 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 78 for recommendations 9 Add the recommended oil 10 Reinstall the fill plug Torque to specification See page 78 for recommenda tions 11 Check for leaks 8 12 Dispose of used oil properly 80 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 68 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 119 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 t
42. ate the filter o ring Check to make sure the o ring is in good condition Install the new oil filter After the filter contacts the engine surface turn it 1 2 turn by hand Remove the dipstick Add the recommended oil See page 74 Reinstall the dipstick Start the engine Allow it to idle for two minutes Stop the engine Check for oil leaks Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Safe Range Add Oil Safe Reinstall the dipstick Discard used oil and filter properly 77 MAINTENANCE Transmission Oil Always check and change the transmission oil at the 2 intervals outlined in the fO T Periodic Maintenance i Chart beginning on page eS 2 68 Maintain the oil level X23 at the bottom of the fill plug hole See page 119 for the part numbers of Polaris products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission Premium AGL Synthetic 15 2 oz 15 ft Ibs 15 ft Ibs 2x4 Gearcase Lubricant 450 ml 20 Nm 20 Nm Transmission Premium AGL Synthetic 20 3 oz 15 ft Ibs 15 ft Ibs 4x4 Gearcase Lubricant 600 ml 20 Nm 20 Nm 78 MAINTENANCE Tr
43. cles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 68 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Enmission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions M Have an authorized Polaris dealer perform these services A WARNING Improperly performing the procedures marked with a W could result in com ponent failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 69 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Steering Pre
44. ct and tighten the black negative cable last Secure the battery hold down strap Verify that cables are properly routed NOTE Cables should be safely tucked away at the front and rear of the bat tery Rey oy 104 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 119 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery L will deteriorate rapidly Check Wet Upper the battery fluid level often Mark Maintain the fluid level between the upper and lower level marks AW satay Hors tone rote Add only distilled water Tap water contains minerals that are harmful to a battery Pb rsez 4011359 Ygi4 B2 WW YUASA MID FOR YUASA BATTERY 1 READING PA 19605 m22462 MADE IN TAIWA 105 MAINTENANCE Battery Battery Charging Conventiona
45. ction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control 29 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recom mended maximum depth see page 62 travel 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 Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly 30 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with imprope
46. d climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual Dy ee 57 OPERATION Driving Safely Driving on a Sidehill Sidehilling A 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 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 Ifthe vehicle begins to tip quickly turn the front wheel downhill if pos sible or dismount on the uphill side immediately 58 OPERATION Driving Safely Driving Downhill A 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 When driving downhill follow these precautions 1 Shift your weight uphill 2 Drive straight downhill 3 Slow down 4 Squeeze the brake leve
47. d practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain A WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempt ing to turn at faster speeds Never turn at excessive speed 25 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees A WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 degrees Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle
48. ding 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 11 SAFETY Operator Safety A WARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle han dles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age 12 SAFETY Operator Safety Safety Training ATV safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV Ride
49. e damage Operate the throttle just enough to maintain a desired speed 65 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 Place the transmission in gear Lock the parking brake Always block the rear wheels on the downhill side Turn the fuel valve off is ee 66 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecft Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are c
50. ecircula tion aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL 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 ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or imprope
51. en the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight uphill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Drive straight downhill Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight uphill Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in this manual SAFETY Operator Safety Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skiddi
52. equently to maintain lighting quality Hot components can cause serious burns to skin Allow lamps to cool before servicing 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 E 30 cover in place Remove the lens cover co 2 Remove the lamp and eens a replace it with a new lamp 3 Test the light for proper rier operation 4 Reinstall the lens cover mN Cover 94 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 95 MAINTENANCE Spark Plugs Spark Plug Rec
53. erating 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 E E forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards e The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling e Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill posi tion e Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 38 FEATURES AND CONTROLS Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake A 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 The auxiliary foot brake is located on the ins
54. 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 Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on 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 Low battery voltage Immediately see your Polaris dealer Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer 121
55. greater dis tance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer A WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water 32 SAFETY Operator Safety A WARNING Operating a damaged ATV can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems A WARNING Safe operation of this rider active vehicle requires good judgement and phys ical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death A WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove
56. h the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only if equipped Utility use plowing Use low range only if equipped Stuck in mud or snow Climbing over large objects from a stopped position Shift the transmission to low range if equipped Care fully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Dry out the PVT See page 101 Inspect clutch seals for damage if repeated leaking occurs 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 48 120 Engine Doesn t Turn Over Possible Cause Blown fuse TROUBLESHOOTING Solution Replace
57. he 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 Drain Plug Torque Torque Demand Drive Premium Demand Drive 5 oz 8 10 ft Ibs 8 10 ft Ibs Unit Hub Fluid 148 ml 11 13 Nm 11 13 Nm 81 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Check l 82 Position the vehicle on a level surface Place the transmission in gear Lock the parking brake an 8 mm Allen wrench Check the oil level Add the recommended oil as needed to bring the level to the bottom of the fill hole threads Reinstall the fill plug Torque to specification See page 81 Remove the fill plug Use MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Change 1 Position the vehicle on a level surface Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use an 8 mm Allen wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use an 11 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 81 9 Add the recommended fluid 10 Reinstall the fill plug Torque to specification 11 Check for leaks 12 Dispose of used oil properly 83 MAINTENANCE Brake Fluid Check brake fluid levels for both brake s
58. he corrosion has been removed Clean and polish the wheel as out lined above 110 MAINTENANCE Cleaning and Storage Storage Tips 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 Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 108 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 76 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 95 111 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 68 e Demand drive unit
59. he 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 2007 Hawkeye 2X4 Hawkeye 4X4 ATV Owner s Manual P N 9920787 2 TABLE OF CONTENTS Know Your Vehicle 0000 00 ee eens 5 Safety 44 40 ecient eee eee mast n aaa 6 Features and Controls 20006 34 Operation issir api nakna aa er ee a its 46 Emission Control Systems 67 Maintenance 000e eee eee eee 68 Adjustments 22200 2c cece eee 115 Polaris Products 200000 cease 119 Troubleshooting 0020ee eee eee 120 Specifications fic sesh eh se ees ieee 124 Warranty fib ola ciara ATOR eRe es 128 Maintenance Log 000ee0es 134 INDOX eve eek eee Cee eae ae 136 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 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
60. hicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 132 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is deliv ered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas r
61. ide 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 ao the rear wheels without Auxiliary Foot Brake skidding Check the brake fluid level frequently for the auxiliary brake system See page 85 39 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 50 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 40 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear Gear selector is located on the Selector right side of the vehicle H High Gear N Neutral R Reverse Whenever the ATV is left unattended always place the transmission in
62. in the owner s manual 23 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could contact the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation A WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when oper ating on unfamiliar terrain Always be alert to changing terrain conditions 24 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slip pery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slip pery or loose terrain could cause loss of traction or loss of control which could result in an accident or over turn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned an
63. ion could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV A WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Q a 30 f Zao Excessive speed increases the operator s we 10 SA 0 so chance of losing control of the ATV which S can result in an accident causing severe X iy D pa injury or death _N ie HOW TO AVOID THE HAZARD j Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 22 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving as A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described
64. l 15 18 1 124 SPECIFICATIONS Hawkeye 2X4 Tires Pressure Front 22x7 12 5 psi Tires Pressure Rear 22x10 12 5 psi 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 Standard Tripmeter Hourmeter Fuel Gauge Standard Tool Kit Standard Jetting Chart ALTITUDE AMBIENT TEMPERATURE Meters Feet Below 40 F 40 F and above Below 5 C 5 C and above 0 900 0 3000 145 140 900 1800 3000 6000 Same main jet Remove 2 air box plugs 1800 2700 6000 9000 Same main jet Remove 4 air box plugs Above 2700 Above 9000 Same main jet Remove 6 air box plugs Above 3000 Above 10000 Same main jet Remove 6 air box plugs Move jet needle clip to position 2 Clutching Chart Altitude Roller Number of Rollers Driven Clutch Meters Feet Weight Spring 0 1500 0 5000 13 g 5412988 8 7043228 1500 3000 5000 10000 10 g 5412986 8 7043228 3000 10000 10 g 5412986 6 7043228 Remove two o
65. l Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 103 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 104 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 A 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 For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe volt
66. mal 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 97 MAINTENANCE Vehicle Immersion 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 If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 10 11 12 98 Move the vehicle out of the water Turn the fuel valve off Check the air box If water is present dry the air box and replace the filter with a new filter Remove the spark plug Loosen the carburetor drain screw and drain the carburetor Turn the engine over several times using the electric start Dry the spark plug Reinstall the pl
67. mission 78 80 Oil and Filter Change 76 77 Oil Level Engine 75 Oil Recommendations 74 Operation on Public Lands 67 Operator Safety 12 33 Override Switch 34 P Parking Brake 38 Parking on an Incline 66 Periodic Maintenance Chart 68 72 Polaris Product List 119 Polishing the Vehicle 109 P Pre Ride Checklist 49 PVT Break In 48 PVE Drying e205 tate cee he eni 101 PVT System 100 101 R Recoil Housing 95 Recoil Starter 42 Reverse Operation 65 Reverse Override Switch 34 Rider Information Center 45 Riding Gear 10 11 S Safety Decals No Passenger Warning 8 Age 16 Warning 8 All Wheel Drive Switch 9 Clutch Cover Warning 9 Discretionary Warning 7 General Waming 6 Hitch Capacity Label 9 Rack Warning Front and Rear 9 Reverse Override Warning 9 Tire Pressure Load Warning 7 Safety Training 13 Severe Use nsec 5a god aoe ak sucks 68 Side Panel Removal 88 Sidehilling 58 Signal Words 14 Spark Arrestor 99 Spark Plugs 96 97 Spring Adjustments 115 Starting the Engine
68. n and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your dealer 122 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug 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 Engine Overheating Possible Cause See your dealer Solution Towing dragging heavy loads Install the accessory oil cooler if the ATV will be used for towing heavy loads drag ging ground surfaces or performing simi lar activities Operating in excessive heat Install the accessory oil cooler if the
69. n turns e 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 SAFETY Safety Decals and Locations Discretionary Warning WARNING e Never operate this ATV on HILLS steeper than 25 degrees lt 25 To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually e REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns e Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle e PARKING BRAKE may relax when used for more than 5 minutes When park ing on grades leave shift in forward 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 Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 930 LBS 422 kg 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
70. ng or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your ATV and always maintain proper tire pressure Never modify an ATV through improper installation or use of acces sories Never exceed the stated load capacity for your ATV 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 17 SAFETY Operator Safety FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our cu
71. nsure proper operation Be Brake fluid Ensure proper level 84 Auxiliary brake Ensure proper operation 39 Front suspension Inspect lubricate if necessary 73 Rear suspension Inspect lubricate if necessary 73 Steering Ensure free operation Tires Inspect condition and pressure 89 Wheels fasteners Inspect ensure fastener tightness a Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels a Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation A Indicator lights switches Ensure operation 34 Engine stop switch Ensure proper operation 35 Air filter pre filter Inspect clean 92 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 35 tric grease when lamp is replaced 94 Brake light tail lamp Check operation apply Polaris dielec 94 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 10 protective clothing 49 OPERATION Starting the Engine A 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 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 gea
72. ommendations CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 124 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification Plug Condition Torque Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft lbs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 97 A WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Remove the left side panel 2 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 3 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 96 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 Tan installation 5 Reverse the procedure for spark plug installation Torque to specification Spark Plug Condition Normal Spark Plug The nor
73. ontrolled 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 The emissions label is located on the recoil cover or stator housing Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 67 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 134 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 Vehi
74. oper dealer set up will void your warranty coverage 128 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 ATV that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV 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 ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHET
75. pery 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 A 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 56 OPERATION Driving Safely Driving Uphill 25 Maximum Whenever traveling uphill follow these precautions Drive straight uphill Avoid steep hills 25 maximum Keep both feet on the footrests Shift your weight uphill Proceed at a steady rate of speed and throttle opening Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle A 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 Avoi
76. polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 109 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 t
77. pposite rollers to maintain clutch balance 125 SPECIFICATIONS Hawkeye 4X4 Gross Vehicle Weight 930 Ibs 422 kg Dry Weight 550 Ibs 250 kg Fuel Capacity 4 5 gal 17 D Engine Oil Capacity 2 qts 1 9 1 Transmission Oil 20 3 oz 600 ml Demand Drive Fluid 5 oz 148 ml Front Rack Capacity 70 Ibs 32 kg Rear Rack Capacity 100 Ibs 45 kg Hitch Tongue Weight Capacity 75 lbs 34 kg Rear rack capacity and tongue weight not to exceed 100 lbs 45 kg Hitch Towing Weight Capacity 750 Ibs 340 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 Minimum Turning Radius 8 in 20 cm 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 4HCS57 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 126 SPECIFICATIONS Hawkeye 4X4
78. r handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 133 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 134 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 135 INDEX A ACCESSOFIES 0 6 2 ee eee eee 113 Age Restrictions 12 Air Filter 00 0 92 All Wheel Drive Switch 35 All Wheel Drive System 43 AWD Switch 04 43 AWD System 0 4 43 B Battery Charging Conventional 106 Charging Sealed 106 107 Conventional 102 Fluid Conventional 105 Installation 104 Removals wa ca 3s ad 103 S
79. r 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 Ifthe 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 50 OPERATION Starting the Engine 8 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts 9 Ifthe engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTE Ifa 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 le
80. r gradually NOTE Before operating your ATV learn how to use the auxiliary brake for emergency situations if single lever brakes become inoperable 59 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 60 OPERATION Driving Safely Turning Around on a Hill K Turn l 2 3 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill Start the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the brake lever until the vehicle is on more level ground 61 OPERATION Driving Safely Driving Through Water Maximum Depth Your ATV 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 befo
81. r injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 20 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways A WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants 21 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seri ously affect operator judgment Reaction time may be slower and operator balance and per cept
82. r or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV in the owner s manual Always maintain proper tire pressure as described in the owner s manual and on safety decals A WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Indus tries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your autho rized Polaris ATV dealer for more information 31 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a
83. rCourse available to you and your eligible family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourses You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals 13 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 A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serio
84. ransmission 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 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz Additives Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT4 Brake Fluid 12 oz 2872893 Engine Degreaser 12 oz 2871956 Loctite 565 Thread Sealant 2871076 Polaris Battery Tender Charger 119 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range if equipped Starting out going up a steep incline Use low range if equipped or turn around using the K turn see page 60 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 Wit
85. re 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 62 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 68 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings 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 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 98 Have the vehicle serviced by your dealer at the first opportunity 63 OPERATION Driving Safely Driving Over Obstacles
86. rs resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Loosen the four handlebar bolts 2 Adjust the handlebar to the desired height 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 Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will a remain at the rear bolts ae 116 ADJUSTMENTS Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 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 the ATV for conditions in your area
87. rush 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 A 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 102 MAINTENANCE Battery A 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 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
88. rvice In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 131 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the ve
89. sation 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 ATV Always install accessories that are approved for ATV use Please see your Polaris dealer 113 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle Stop the engine Place the transmission in gear Lock the parking brake Turn the fuel valve off Secure the fuel cap oil cap and seat Remove the key to prevent loss during transporting DN a Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 114 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 115 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handleba
90. stomers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 18 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCourse offered by Polaris through the SVIA They should then reg ularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information abo
91. the engine stop switch is in the RUN position A WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV 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 All Wheel Drive Switch 4x4 Models See page 43 for all wheel drive information 35 FEATURES AND CONTROLS Throttle Lever A WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV 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 Engine speed and vehicle move ment are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns 4 9 to idle when the lever is released SA LI g This ATV is equipped with Polaris lt Electronic Throttle Control ETC Ba gt which is designed to reduce the risk hag of a frozen or stuck throt
92. the footwell to the fenders 3 Remove the footwell Rivets 88 MAINTENANCE Tires Refer to the specifications section beginning on page 124 for recom mended tire type size and pressure A WARNING Operating your ATV 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 ATV 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 Tire Tread Depth Always replace tires 1 8 3 mm Z when tread depth is worn to 1 8 3 mm or less OR aS 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 89 MAINTENANCE Tires Wheel Removal 1 Position the vehicle on a level surface 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 90 MAINTENANCE Tires Wheel Installation A WAR
93. tle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease A 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 36 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 A WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 37 FEATURES AND CONTROLS Parking Brake A WARNING Operating the ATV while the parking brake is engaged could result in an acci dent and serious injury or death Always check to be sure the parking brake is disengaged before op
94. torages hs ach Gabe aes 105 BOOS ga seat aetna oho E SA 11 Brake Fluid 84 85 Brake Inspections 86 Brake Lever 005 37 Brake Foot 0000 39 Brake Parking 38 Brakelight 94 Brakes ot 3 ee oie Mie tas Se eS 86 Break In Period 47 48 Breather Filter 92 Cc Camber Adjustment 115 Carburetor 004 117 Carburetor Adjustment 117 Catt Olena tit aaa a EEEE 52 53 Caster Adjustment 115 Chokei neo anaes a asia a 40 Chrome Wheel Care 110 Cleaning and Storage 108 113 Clothing sucess esas noera 11 Clutching Chart 2X4 125 Clutching Chart 4X4 127 Cold Weather Operation 51 Consumer Product Safety 18 Corrosion Removal Chrome 110 Crankcase Emission Control 67 136 D Demand Drive Fluid 81 83 Drive Belt Wear Burn 120 Drivetrain Break In 48 Driving Downhill 59 Driving in Reverse 65 Driving on a Sidehill 58 Driving on Slippery Surfaces 56 Driving Over Obstacles 64 Driving Procedures 54 Driving Safely 54 66 Driving Through Water 62 63 Driving Uphill 0 ST E Electromagnetic Interference 67 Emissions Limited Warranty 133 Engaging AWD
95. ts 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 Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 43 CFR 8340 1 c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 130 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Se
96. ug or install a new plug Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If necessary repeat the drying proce dure Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 101 for drying out the PVT MAINTENANCE Spark Arrestor A 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 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 ae A Cy 3 Lock the parking brake x 4 Remove the arrestor y T clean out plug from the Clean Out Plug bottom of the muffler 5 Start the engine 6 Quickly squeeze and release the throttle lever several times to purge carbon from the system
97. us injury or death A 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 14 SAFETY Operator Safety A WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourse Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets Never operate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or
98. ut the ATV RiderCourses contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child eh under the minimum age recommendation oper ates an ATV lt 1 6 Even though a child may be within the recom mended age group for operating some ATVs he she may not have the skills abilities or judg ment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV 19 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces the oper ator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers A WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operat ing on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and o
99. ver 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 CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the ATV 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 51 OPERATION Hauling Cargo Your ATV 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
100. w it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Driving Safely Turning the Vehicle Your ATV 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 A 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 55 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 slip
101. y Do not install it in any other product Always make sure the PVT housing is securely in place during operation 100 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 F a 17 mm wrench a flat screw J 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 101 MAINTENANCE Battery Your ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Conventional Battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire b
102. ystems before each ride Always maintain brake fluid at the recommended level Do not overfill A 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 If the fluid level is low add DOT 4 brake fluid only See page 119 for the part numbers of Polaris products A 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 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 84 MAINTENANCE Brake Fluid Hand Brake Master Cylinder 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 si 8 Indicator 1 Position the vehicle on a Window level surface Make sure the handlebars are str

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