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1. 96 PVT System 95 96 R Rear Spring 108 Recoil Housing 94 Recoil Starter 37 Reverse Override Switch 31 Rider Information Center 41 S Safe Riding 10 Safety i ose ees hee hs 6 30 Safety Decals and Locations 6 9 S Safety Training 11 Severe USe eese etre 64 Side Panel Removal 86 Sidehilling 54 Spark 93 Spark 90 91 Starting the Engine 46 47 Steering Assembly 80 Stop 31 Storage ver 103 106 Storage Tips 104 106 Switches i e ROSE 31 T Taillight 89 Throttle Cable Freeplay 111 Throttle 32 Ties sien eos cade wee 81 Toe Alignment 80 Transmission Oil 73 74 Transporting the ATV 107 Trip 41 Troubleshooting 113 115 Turning Around on a Hill 56 57 V Vehicle Identification Numbers 5 Vehicle Immersion 92 Warranty 122 126 Wheel Nut Torque Specifications 83 Wheel Replacement 82 83 131
2. POLARIS The Way Out 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 without proper training or instruction e Operate on public roads A collision can occur with another vehicle x e Operate at speeds too fast for your skills or the conditions 4 Use ALCOHOL or DRUGS before or while operating this vehicle e Carry Passengers i ALWAYS 1507 Avoid paved surfaces which may adversely affect handling and control 4 eUseproper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns eWear eye protection helmet and protective apparel js set READ OWNER S MANUAL AME FOLLOW ALL INSTRUCTIONS AND WARNINGS Y X m m T Ei 3 LR T E NE V UA SN vr nee AT Ue 2 A ULT 1 H S n PE 1 Eid ps 4 T RAS Jo gt gg Part No 9920202 C PELARIS PRINTED IN THE USA The Way Out 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 assistan
3. 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 under the minimum age recommendation operates an ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment 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 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident 7 and injury to the eT p 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 4 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 Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudde
4. 29 SAFETY Operator Safety A A 30 WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING Safe operation of this rider active vehicle requires good judgement and physical 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 CAUTION 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 CONTROLS Engine Electrical Switches 4 WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open 1 Mode Reverse Override Switch 1 This vehicle is equipped with a reverse speed limiter system To gain additional power while backing press the override switch NOTE The override switc
5. 2 Grasp the top of the side panel and pull it outward to remove it O Footwell Removal 1 Remove the two 2 screws 1 on the bottom of the footwell 2 Usea flat screwdriver S awe or sidecutters to E 51 remove the 10 plastic rivets 2 securing the LM i footwell to the fenders 3 Remove the footwell 86 MAINTENANCE AND LUBRICATION 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 4 WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Allow lamps to before servicing 87 MAINTENANCE AND LUBRICATION Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 1 Position the vehicle on a level surface The headlight should be approximately 25 ft 7 6 m from a wall 25 ft 7 6 m 2 Place the transmission in neutral N _ 3 Lock the parking brake 00 4 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height
6. NOTE Include rider weight on the seat when measuring 5 Start the engine and turn the headlight switch to high beam 6 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 1 cm below the mark on the wall 7 Loosen the phillips screw at the rear of the headlamp 8 Adjust the beam 9 Tighten the screw 88 MAINTENANCE AND LUBRICATION Lights Headlamp Replacement 1 Turn the back of the headlight harness 1 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 clockwise to secure the headlamp Taillight Brakelight Replacement 1 From the rear of the brakelight remove the two screws 1 holding the lens cover in place Remove the lens cover 2 2 Remove the lamp 3 and replace it with a new lamp 3 Test brakelight to ensure operation 4 Reinstall the lens cover 89 MAINTENANCE AND LUBRICATION Spark Plugs Always use the spark plugs recommended for your ATV Refer to the specifications section beginning on page 116 for the recommended spark plug type and gap CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The s
7. toward the handlebar The front and rear 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 4 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 33 CONTROLS Parking Brake 4 amp WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Locking the Parking Brake 1 Place the transmission in gear 2 Squeeze and release the brake lever two or three times then squeeze and hold 1 3 Push the park brake lock 2 forward to engage the brake Release the brake lever 4 release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards The parking brake may relax if left on for a long period of time AI ways block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to
8. 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 WW gpoaccess gov ecfr 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 exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer 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 63 MAINTENANCE AND LUBRICATION 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
9. above ALTITUDE 0 1800 142 5 187 5 Meters 0 6000 Feet 1800 3700 1375 182 5 6000 12000 Clutching Chart Altitude Driven Clutch Meters Feet Spring 0 1800 14 g Yellow 7043212 0 6000 5412989 1800 3700 12 g Red 7043212 6000 12000 5412987 118 SPECIFICATIONS 2006 Hawkeye 4X4 Gross Vehicle Weight Fuel Capacity Engine Capacity Transmission Oil Front Gearease weight not to exceed 100 16 Towing Capuc Turn Radius Ground Clearance Longi Width Height Wheel Base Dry Weigh Engine Model Number Type Lubrication Bore x Stroke Displacement Compression Rai Engine Cooling Alternator Output watts Carburetion Main Jt Pics Needle a Pio Air Jl Tet Needle Timing 10 2 1500 RPM 30 2 5000 RPM Spark Plug Type Gap NGK CR8E 031 in 8 mm 119 SPECIFICATIONS 2006 Hawkeye 4X4 Drive System Type PVT Shift Type Side Lever H N R Front Drive ratio Final Drive ratio Front Suspension Mac Strut Rear Suspension Progressive Rate Swing Arm Shock Adjustment Auxiliry Brake Park Brake Brake Ligh Batten DC Plug in Rear Windshield Neural Indict Speedometer Odometer Tripmeter Standard Hourmeter Fuel Gauge Tool Kit 120 SPECIFICATIONS 2006 Hawkeye 4X4 Jetting Chart AMBIENT Below 40 F 40 and above TEMPERATURE Below 5 C 5 and above ALTITUDE 0 1800 142 5 187 5 Meters 0 6000 Feet 1800 3700 13
10. clean if needed filter if equipped General 3M 500 800 Lubricate all fittings pivots lubrication cables etc ETC Switch Carburetor float 5 500 800 Drain bowl periodically and bowl prior to storage Choke cable Throttle Cable OH 500 800 Inspect adjust lubricate replace if necessary 0H 500 800 Inspect adjust lubricate replace if necessary Carburetor air 5 6M 500 800 Inspect ducts for proper intake ducts sealing air leaks flange Drive belt 100 H 1000 1600 Inspect adjust replace as needed Engine oil change 100 H ey 1000 1600 Perform a break in oil change at one month Oil filter change 100 H 1000 1600 Replace with oil change p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 66 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Oil tank vent hose 100 H 1000 1600 Inspect routing condition if equipped 100 H Daa 1000 1600 Inspect adjust Valve clearance Fuel system filter 100 H 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years 100 H 1000 1600 Inspect eb 12M 12M 12M 100 H 2M 1000 1600 Inspect replace as needed 2M 2M 2M 2M Engine mounts Exhaust muffler pipe Spark plug Igniti
11. 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 mowers 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 15 SAFETY Operator Safety 4 amp WARNING 16 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 certified training course offered by Polaris Operators should regularly practice the skills learned in the course and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764
12. death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE 12 A note will alert you to important information or instructions SAFETY Operator Safety 4 amp 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 Beginners should receive training from a certified instructor Contact an authorized Polaris ATV dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you 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 safe ty 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 face shield gloves boots a long sleeved shirt or
13. draining the housing 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 crankcase drain is opened 94 MAINTENANCE AND LUBRICATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 95 MAINTENANCE AND LUBRICATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system Dry it out before operating 1 Move the vehicle out of the water 2 Remove the PVT drain plug A Use a 17mm wre
14. failure Overheated engine Engine Overheating Possible Cause Towing dragging heavy loads Operating in excessive heat Solution Clean radiator screen and core Clean engine exterior See your Polaris dealer Solution Install the accessory oil cooler if the ATV will be used for towing heavy loads drag ging ground surfaces or performing simi lar activities Install the accessory oil cooler if the ATV will be operating longer than 1 2 hour in temperatures above 100 F 38 C 115 SPECIFICATIONS 2006 Hawkeye 2X4 Gross Vehicle Weigh Fuel Capacity Engine Oil Capacity Transmission Oi Front Gearase weight not to exceed 100 Ibs Towing Capacity Radius Ground Clearance Tenth Width Heighi Dry Weigh Wheel Base Lubrication Bore x Stoke Displacement Compression Rat Engine Cooling Alternator Oupul Carbareton Plor Needle Jel Pilot Aire Ter nition Timing Spark Flug Type Gap 116 SPECIFICATIONS 2006 Hawkeye 2X4 Shit Type Final Drive Front Suspension Mac Strut Rear Suspension Progressive Rate Swing Arm Shock Adjustment Auxiliary Brake Park Brake Brake Ligh Batten DC Plug in Rear Electric Stn Windshield Neural Indict Speedometer Odometer Tripmeter Standard Hourmeter Fuel Gauge Tool Ki 117 SPECIFICATIONS 2006 Hawkeye 2X4 Jetting Chart AMBIENT Below 40 F 40 and above TEMPERATURE Below 5 C 5 and
15. keys are lost the ignition switch must be replaced Vehicle Model Number Frame VIN 1 Engine Serial Number 2 Key Number 3 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 always read and follow the instructions of the decals on the 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 A WARNING Improper ATV use can result in SEVERE INJURY or DEATH DOO ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARI
16. loading information NEVER ride as a passenger Passengers can cause loss of control resuiting in SEVERE INJURY or DEATH 7172566 ATTENTION Operation of this vehicle without the air Specific carburetor jetting and filter element will severely damage the adjustments are required depending engine on temperature and altitude See Clean pre filter element often more your Owner s Manual frequent cleaning required in dusty Factory setting conditions Do not operate vehicle 40 to 80 F at 0 3000 feet without pre filter 5 to27 at 0 900 meters 7170007 SAFETY Safety Decals and Locations A WARNING Ks Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7172559 V VA FT AWARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 70 Ibs 32 kg Rear 100 Ibs 46 kg 7173740 SAFETY Safety Decals and Locations A WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in AWD See Owner s Manual 7172564 AWD models ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning This may cause
17. odometer displays without a decimal point Mode 3 Hour Meter This mode logs the total hours the engine has been in operation 41 OPERATION Fuel Safety 4 amp WARNING 42 Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the ATV is stored or parked WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 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 procedures for a proper break in Careful treatment of a new engine and drive components will resu
18. 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 92 Have the vehicle serviced by your dealer at the first opportunity 59 OPERATION Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches 4 WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 60 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Always avoid backing downhill 2 Back slowly 3 When in reverse apply the brakes lightly for stopping 4 Avoid turning at sharp angles in reverse 5 Never open the throttle suddenly while backing 4 amp 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
19. 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 The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 61 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in gear 3 Lock the parking brake 4 Always block the rear wheels on the downhill side as shown in the illustration 5 Turn the fuel valve off 62 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 Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands
20. park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 34 CONTROLS Auxiliary Brake 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 sideways causing loss of control and serious injury or death Your Polaris ATV has an auxiliary brake 1 for added safety It s located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding 35 CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 46 for correct choke and throttle settings during starting Fuel Tank The fuel tank filler cap 1 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum octane level of 87 2 Fuel Valve The fuel valve 2 is located on the bottom of the fuel tank Access the fuel valve through the right front wheel well or from the fron
21. 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 come into contact with 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 4 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 Mere HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 21 SAFETY Operator Safety 4 amp WARNING 22 POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of cont
22. severe drive shaft and clutch damage See your Owner s Manual 7079780 AWD models OVERRIDE SWITCH Reverse speed is limited Reverse override is controlled by the override switch See your Owner s Manual 7079906 2WD models MANUFACTURED BY POLARIS IND INC DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE EST UN V HICULE TOUT TERRAIN QUI N EST PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS PATENT NOTICE Mfd by Al Terrain Vehicle Division Polaris Industries Inc under one or more of the following patents Other patents pending U S Patents 4697665 5036039 5975624 6016943 6092877 6149540 6224134 6270106 6340186 0378080 D389440 0400143 Canadian Certification Decal 7171492 TRAILER MAX WEIGHT 750 LBS 840 KG ON LEVEL GROUND HITCH MAX VERTICAL WEIGHT 75 LBS 34 KG 7173739 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet that meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Fou
23. slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period 44 OPERATION Pre Ride Inspection 4 amp WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Pre Ride Checklist Page Ensure proper operation Ensure proper level Ensure proper operation Inspect lubricate if necessary 68 Inspect lubricate if necessary 68 Ensure free operation nspect condition and pressure nspect ensure fastener tightness nspect ensure tightness IEEE Ensure proper levels Brake system lever travel Ensure proper operation Ensure operation Ensure proper operation speci denn Eu Drain deposits whenever visible Headlamp Check operation apply Polaris dielec tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec tric grease when lamp is replaced Riding gear Wear helmet goggles protective 0 clothing wo C icable Coolant hoses if applicable Inspect for leaks j A Coolant level if applicable Ensure proper level 45 OPERATION Starting the Engine 4 amp 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 enclose
24. tire pressure as specified SAFETY Operator Safety 4 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 Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information 4 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 greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 48 4 amp 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
25. 1 102 Battery Fluid Conventional 100 Battery Installation 99 Battery Removal 98 Battery Storage 100 Belt 44 Brake Fluid 77 78 Brake Lever 33 Brake Auxiliary 35 Brakelight 89 Brakes ha eg 77 79 Break In 43 44 Breather 84 85 Camber and Caster 108 Carburetor Idle RPM 110 Choke ehem EI Seles 36 Cleaning 103 106 Clutch 44 Clutching Chart 2X4 118 Clutching Chart 4X4 121 Cold Weather Operation 47 Controls ize Ra 31 38 Crankcase Emission Control System 63 D Drivetrain Break in 44 Driving Downhill 55 Driving in Reverse 61 Driving on Slippery Surfaces 52 Driving Over Obstacles 60 Driving Procedures 50 Driving Through Water 58 59 Driving Uphill 53 E Electrical Switches 31 Emission Control Systems 63 130 E Engaging Front Gearcase 39 Engine Break in 44 Engine Stop Switch 31 Equipment Modifications 15 Exhaust Emission Control System 63 F Features v ance Sigh T 39 41 Footwell Removal 86 Front Gearcase Oil 75 76 Front
26. 75 182 5 6000 12000 Clutching Chart Altitude Driven Clutch Meters Feet Spring 0 1800 14 g Yellow 7043212 0 6000 5412989 1800 3700 12 g Red 7043212 6000 12000 5412987 121 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris 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 transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR A
27. 8 will remain at the rear bolts 109 ADJUSTMENTS Carburetor Idle RPM 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 346 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 operation 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 engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area 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 Operate the engine for about five minutes 4 Turn the carburetor idle adjuster 1 either in or out until the desired idle RPM is reached Turning the adjuster in clockwise will raise RPM Turning the adjuster out counterclockwise will lower RPM 110 ADJUST
28. AINTENANCE AND LUBRICATION Engine Oil Oil Check 1 Position the vehicle on a E level surface 2 Place the transmission in neutral 3 Lock the parking brake 4 Start the engine Allow it to idle for 30 seconds Turn the engine off 5 The oil dipstick and fill JS hole are located behind the Xe A 5 T recoil on the right side of x the ATV Remove the dipstick Wipe it clean 6 Reinstall the dipstick completely 7 Remove the dipstick Check the E oil level 8 Add oil as needed to bring the level between the minimum and maximum marks Do not overfill 9 Reinstall the dipstick 70 MAINTENANCE AND LUBRICATION Engine Oil Oil Change 1 Position the vehicle on a E 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 Turn the engine off 5 Clean the area around the drain plug 4 CAUTION Hot oil may result in serious burns Do not allow hot oil to contact skin 6 Place a drain pan under the vehicle 7 Remove the drain plug Use a 6mm Allen wrench 8 Drain the oil 9 Reinstall the drain plug with a new sealing washer 10 Torque to specification See page 69 NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks
29. MENTS Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 1 5 mm to 1 8 3 2 mm freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 1 2 3 111 POLARIS PRODUCTS Part No 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 Transmission Lubricants 2873602 2873603 2871693 2872276 2870465 2871694 2872277 2871322 2871423 2871460 2871518 2871551 2871312 2871329 2872073 2872348 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 112 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Blown fuse Replace fuse Low battery voltage Recharge battery to 12 5 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 Solution Clogged fuel valve or filter Water i
30. NG 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 27 SAFETY Operator Safety 4 amp WARNING 28 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 recommended maximum depth see page 58 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 WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure 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 Always maintain proper
31. NTROL 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 grass 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 49 OPERATION Driving Procedures 50 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up then 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 Vehicle speed is controlled by the amount of throttle opening Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Making Turns 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 tir
32. S DEALER FOR A REPLACEMENT 2 1997 2000 7172560 4 WARNING Never operate this ATV on HILLS steeper than 25 degrees 285 To prevent flipover hilly terrain when going up down use throttle and brakes gradually REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle When this ATV is not in operation or unattended place shift in the park position 7172561 SAFETY Safety Decals and Locations A 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 2X4 930 LBS 422 kg 4X4 950 LBS 431 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 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
33. TV 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 proper dealer set up will void your warranty coverage 122 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 racing 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 components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONL
34. Wheel Hub Tightening 81 Fuel Filter eor 36 Fuel Safety 42 Fuel Tank ll 36 Fuel Valve nod Rs 36 G Gear 1 38 H Handlebars 109 Hauling 48 49 Headlamp Replacement 89 Headlight Beam Adjustment 88 Hour Meter 41 Instrument Cluster 40 41 J Jetting Chart 2X4 118 Jetting Chart 4 4 121 K llo nM RERO 56 L Light Switches 33 Lights nep EUER 87 89 Lubrication Guide 68 M Main Switch 31 Maintenance 64 107 Maintenance Log 127 Making Turns 51 Master Cylinder Foot Brake 78 Master Cylinder Handlebar 78 Mode Reverse Override Switch 31 N Noise Emission Control System 63 Odometer 41 Oil Change 71 72 Oil Check 70 Oil Engine 69 72 Oil Front Gearcase 75 76 Oil Transmission 73 74 Operation 42 62 Operator Safety 11 30 P Parking Brake 34 Parking an Incline 62 Periodic Maintenance Chart 64 67 Polaris Products 112 Pre Ride Inspection 45 Premium 4 Synthetic 69 PVT Break in 44 PVT Drying
35. Y 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 vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was pur chased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Vehicles registered to Government officials or mili tary 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 126 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 127 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 128 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 129 INDEX A Age Restrictions 11 Air Filter sie 84 85 All Wheel Drive 39 All Wheel Drive Switch 31 Automatic Transmission 38 AWD eel csse E EE US 39 AWD Switch 31 B Battery 98 102 Battery Conventional 97 Battery Charging Sealed 10
36. Y REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED 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 123 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR 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 limitations 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 deale
37. ad and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Safety Training When you purchased your new your dealer offered a hands on safety training course that covers all aspects of vehicle safety 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 from a party other than a Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of the ATV 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 11 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or
38. and lubricate the entire vehicle with Polaris Premium Season Grease Battery Maintenance Conventional Remove the battery and add distilled water to the proper level Do not use tap water which may contain minerals that reduce battery life Apply dielectric grease to the terminal bolts and terminals Charge the battery at 1 4 amps or less until the specific gravity of each cell is 1 265 or greater Store the battery in a cool dry place Charge can be maintained easily by using Polaris Battery Tender charger PN 2871076 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 Check the fluid level monthly Battery Maintenance Sealed Remove the battery and recharge it as outlined on page 101 Store the battery in a cool dry place Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 106 MAINTENANCE AND LUBRICATION Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn the engine off Remove the key to prevent
39. ce WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience 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 service needs during and after the warranty period We also take great pride in our complete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out Copyright 2005 Polaris Sales Inc All information contained within this publication is based on the la
40. cle 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 56 SAFETY Operator Safety 4 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 procedures as outlined in the owner s manual 4 WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction 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 4 WARNI
41. 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 97 MAINTENANCE AND LUBRICATION Battery Battery Removal 1 Place the transmission in gear 2 Lock the parking brake 3 Open the front cover 4 Remove the hold down strap holding the battery in position 5 Onconventional batteries remove the battery vent tube 6 Disconnect the black negative battery cable first 7 Disconnect the red positive battery cable next 8 Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte 4 CAUTION 98 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 MAINTENANCE AND LUBRICATION Battery Battery Installation 1 Setthe battery in the battery holder 2 With conventional batteries install the battery vent tube sealed batteries do not have a vent t
42. d area Place the transmission in neutral Lock the parking brake Turn the fuel valve on Bo po E Sit on the vehicle NOTE If starting a warm engine do not use the choke Excessive use of the choke can cause the spark plug to become wet fouled If the engine has cooled to a point where it does not readily start intermittent use of the choke pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 5 Ifstarting a cold engine 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 operation as excess fuel washing into the engine oil will increase wear on engine components 6 Turn the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 46 OPERATION Starting the Engine 7 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 vehicle starts If the engine does not start release the starter and wait five seco
43. ding 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 37 CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 is located on the right side of the vehicle H High Gear N Neutral R Reverse 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 Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake 38 FEATURES Wheel Drive AWD System AWD Models The Wheel Drive system is activated by the AWD switch 1 on the right handlebar When the NES switch is on 2X4 the ATV is in j two wheel drive at all times When xc the switch is on AWD the ATV is 1 in all wheel drive When in AWD the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 31 There is
44. duce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Towing Install the accessory oil cooler if the ATV will be used for towing heavy loads dragging ground surfaces or performing similar activities 48 OPERATION Hauling Cargo 4 amp 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 one rack only increases the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle 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 CO
45. e 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 technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds 4 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 51 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 52 Slow down when entering slippery areas Engage AWD if equipped before wheels begin to lose traction Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can resu
46. er for free replacement CAUTION High water pressure may damage ATV components Polaris recommends washing the ATV by hand or with a garden hose using mild soap Certain products including insect repellants and chemicals will damage plastic surfaces Do not allow these types of products to come into contact with the ATV If a high pressure water system is used exercise extreme caution to avoid damaging wheel bearings radiator transmission seals body panels brakes and warning labels Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Unless it has a special finish your ATV can be waxed with any non abrasive automotive paste wax Do not wax models that have a camouflage finish 103 MAINTENANCE AND LUBRICATION 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 necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals Stabilize the Fuel Fill the fuel tank Add Polaris Carbo
47. escending 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 55 Always check the terrain carefully before descending a hill Shift your weight backward 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 24 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD EON Improperly crossing hills and Wa e SR turning on hills K 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 manual See page 56 Use extra caution when turning 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 25 SAFETY Operator Safety WARNING 26 POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehi
48. ever Engine speed and vehicle movement are controlled by OD pressing the throttle lever 1 f The throttle lever is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 4 WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms 32 CONTROLS Light Switches The light switch 1 is located on the left handlebar It s used to turn the lights on and off NOTE The lights won t work unless the key is in the ON position and the shut off switch is in the RUN pasition 4 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 Brake Lever The front and rear brakes are applied by squeezing the brake lever 2
49. faces 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 14 SAFETY Operator Safety 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 FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that
50. fi cials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service 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 be fore you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty cov erage You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 125 WARRANT
51. fore installation a NOTE Refer to the specifications section beginning on page 116 for the recommended spark plug type and gap 5 Reverse the procedure for spark plug installation using the recommended spark plug 6 Torque to 12 ft 165 16 Nm 91 MAINTENANCE AND LUBRICATION 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 Move the vehicle out of the water 2 Turn the fuel valve off Remove the spark plug See page 91 4 Drain any water found in the air box Replace the air filter if it became wet we 5 Loosen the carburetor drain screw 1 and drain the carburetor 6 Turn the engine over several times using the electric start 7 Dry the spark plug and reinstall or replace it with a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE f water has been ingested into the PVT follow the procedure on page 96 for drying out the PVT 92 MAINTENANCE AND LUBRICATION Spark Arrestor To remove accumu
52. g 4 WARNING An overheated battery could 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 NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Voltage Charge Time Charge Using constant current charger 2 standard amps specified on top of battery 10096 12 8 13 0 volts None check at None required 3 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 0 75 12 0 12 5 volts Needs Charge 5 11 hours 25 50 11 5 12 0 volts Needs Charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs Charge At least 20 hours 102 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 112 for the part numbers of Polaris products Washing the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots Avoid the use of harsh cleaners which can scratch the finish NOTE f warning and safety labels are damaged contact your Polaris deal
53. h also allows activation of AWD in reverse if the AWD switch is on This switch is also used to toggle through the different modes of the rider information center See page 40 Engine Stop Switch 2 The engine will not start or run when the switch is in the OFF RUN OFF OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency Main Switch 3 To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts NOTE Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle including lights To stop the engine slide the stop switch either right or left to the OFF position All Wheel Drive Switch AWD Models 4 See page 39 31 CONTROLS 4 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 Throttle L
54. hanges 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 backward 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 Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing 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 procedure 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 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 skidding or sliding On slippery sur
55. hese services 4 WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Miles Km ee ren Make adjustments need F Pre Rid ed See Pre Ride Checklist gt Frontsuspension Weide Sn page a5 gt ear suspension Pere pe j pe paene meme meme sess resse Uem Fane testes Pommes Air filter pre filter Daily Inspect clean often replace as needed Air box sediment Daily Drain deposits when visible tube Headlamp tail Daily Check operation apply lamp dielectric grease if replacing 65 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Air filter Weekly Inspect replace as needed main element Recoil housing Weekly Drain water as needed check often if operating in wet conditions Brake pad wear Monthly 100 160 Inspect periodically Monthly 200 320 Check terminals clean test Monthly 250 400 Inspect level change yearly Transmission oil Monthly 250 400 Inspect level change yearly Engine breather 25H Monthly 250 400 Inspect
56. il it s pointing across the hill or slightly downward Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the service brake until the vehicle is on more level ground 57 OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests 1 Follow these procedures when operating through water Determine water depths and current before crossing Choose a crossing where both banks have gradual inclines Proceed slowly avoiding rocks and obstacles if possible After crossing dry the brakes by applying light pressure to the lever until braking action is normal Bw 58 OPERATION Driving Through Water After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 64 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings 4 amp 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
57. 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 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 manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 13 SAFETY Operator Safety 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 ter rain carefully before ascending a hill Never climb hills with exces sively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear c
58. k the wheel nut torques occasionally and when they ve been loosened for maintenance service Front Wheel Nuts 27 ft Ibs 37 Nm Rear Wheel Nuts 27 ft lbs 37 Nm 83 MAINTENANCE AND LUBRICATION Air Filter Breather Filter Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 66 1 Position the vehicle on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the seat 5 Unlatch the air box clips 1 Remove the air box cover 6 Loosen the hose clamp 2 7 Remove the air filter 3 8 Remove the sleeve 4 from the filter 9 Wash the sleeve in soapy water then rinse and let dry 10 Remove the breather filter 5 11 Wash the breather filter in soapy water then rinse and let dry 84 MAINTENANCE AND LUBRICATION Air Filter Breather Filter 12 Reinstall the breather filter CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service 13 Reinstall the sleeve over the air filter Replace the filter if needed 14 Reinstall the air filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur 15 Reinstall the air box cover and the seat 85 MAINTENANCE AND LUBRICATION Side Panel Removal 1 Remove the seat A S
59. keep brake fluid at an adequate level Do not overfill 4 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 recommended level Do not overfill If the fluid level is low add DOT 3 brake fluid only See page 112 for the part numbers of Polaris products 4 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 Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation 77 MAINTENANCE AND LUBRICATION Brakes Brake Fluid Master Cylinder Handlebar The master cylinder 1 is located on the left handlebar Maintain the fluid level 1 4 6 3 mm below the top edge of the master cylinder Do not overfill 1 Position the vehicle on a level surface Make sure the handlebars are straight 2 View the fluid level through the indicator window eye on the to
60. lated carbon clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart 4 WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas 1 Remove the bolt A and remove the arrestor B from the end of the muffler 2 Usea non synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air CA 3 Inspect the screen for wear and damage A replace the arrestor if damage is found 7 4 Reinstall the arrestor B 5 Torque the bolt to 7 ft Ibs 9 5 Nm 93 MAINTENANCE AND LUBRICATION Recoil Housing Always drain the recoil housing 1 after operating the vehicle in wet conditions Always remove the drain plug before storing the vehicle NOTE Water will enter the recoil housing if the starter handle 2 is disengaged from the rope guide when under water 1 Place the transmission in gear 2 Lock the parking brake 3 Using a wrench remove the drain screw 3 on the bottom of the recoil housing 4 Reinstall the screw after
61. le The transmission fill plug 1 is located on the left side of the under the rear fender behind the wheel The drain plug 2 is located behind the wheel well See page 112 for the part numbers of Polaris products Cil 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 15mm wrench 5 Check the oil level 6 Add the recommended oil as needed Do not overfill 7 Reinstall the fill plug Torque to specification 73 MAINTENANCE AND LUBRICATION Transmission Oil Oil Change 1 Position the vehicle on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use a 15mm wrench 5 Remove the drain plug Use a 15mm wrench GP 6 Drain the fluid into a drain pan S 7 Clean and reinstall the drain plug Torque to specification See page 73 8 Add the recommended oil See page 73 9 Reinstall the fill plug Torque to specification See page 73 10 Check for leaks 74 MAINTENANCE AND LUBRICATION Front Gearcase Oil Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Front Gearcase Premium Demand Drive 5 oz 8 10 ft Ibs 8 10 ft Ibs Hub Fluid 148 ml 11 13 Nm 11 13 Nm Always check and change the front gearcase oil at the intervals outlined in the Pe
62. loss during transporting 2 Place the transmission in gear 3 Lock the parking brake 4 Turn the fuel valve off Be sure the fuel cap oil cap and seat are installed securely 6 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 107 ADJUSTMENTS Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension Always adjust both sides equally NOTE Accessory springs are available through your Polaris dealer 108 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference 4 amp WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Loosen the four bolts 1 2 Adjust the handlebar to the desired height 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
63. lt 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 OPERATION Driving Uphill Whenever traveling uphill follow these precautions Always travel straight uphill Avoid steep hills 25 maximum Keep both feet on the footrests Transfer your weight forward Proceed at a steady rate of speed and throttle opening Gv Bo B ES Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 4 WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 53 OPERATION Sidehilling 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 the most dangerous type of driving encountered and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautio
64. lt in more efficient performance and longer life for these components NOTE Install the accessory oil cooler if the ATV will be used for towing heavy loads dragging ground surfaces or performing similar activities Install the accessory oil cooler if the ATV will be operating longer than 1 2 hour in temperatures above 100 F 38 C CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use 43 OPERATION Break In Period Engine and Drivetrain Break in 1 2 Fill the fuel tank with gasoline See page 36 Check the oil reservoir level on the dipstick See page 70 Add oil if necessary to maintain the level between the safe and add marks Drive slowly at first Select an open area that allows room to familiarize 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 45 Pull only light loads During the break in period change both the oil and the filter at 20 hours 200 miles or one month whichever comes first 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
65. n Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor Tum the fuel valve off Drain the carburetor bowl Oil and Filter Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter See page 84 Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter See page 84 Fluid Levels Inspect the following fluid levels and change if necessary Front demand drive unit front gearcase Transmission Brake fluid change every two years or as required if fluid looks dark or contaminated 104 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Fog the Engine 1 Remove the spark plug and add 2 3 tablespoons of 10W40 engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak 2 Reinstall the spark plug Torque to 18 ft Ibs 24 Nm 3 Apply dielectric grease to the inside of the s
66. n turns or stops 17 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV on is public streets roads or a highways Sud WHAT CAN HAPPEN The ATV could collide Puy 18 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 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without A an approved helmet A increases the risk of a 4 ees EA severe head injury or z P oce J 7 death in the event of an i VILIS E O E nY 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 wes SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while opera
67. nch a flat screwdriver or the spark plug wrench 3 Allow the water to drain Reinstall the drain plug 4 Start the engine Place the transmission in neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 96 MAINTENANCE AND LUBRICATION Battery Your ATV may have either a sealed battery which requires little maintenance or a conventional battery 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 Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 4 WARNING Battery electrolyte is poisonous It
68. nd adjustment 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 toe out 1 Setthe handlebars in a straight ahead position NOTE The steering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tiean 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 1 front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 Rear measurement should be 1 16 1 8 1 5 3 2 mm more than the front measurement NOTE f you discover improper alignment see your Polaris dealer for service 80 MAINTENANCE AND LUBRICATION 4 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 tire
69. ndation label 2 Eye Protection Do not depend on sunglasses for proper eye protection pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings 72 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with heels like moto cross boots 5 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 10 SAFETY Operator Safety 4 WARNING Failure to follow the warnings contained in this manual can result in serious injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles 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 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 Re
70. nds Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts 8 Ifthe engine slows or stops position the choke knob half way in to allow proper engine warm up 9 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 contaminants such as water or excess fuel in the bottom of the oil tank Water in the bottom of the tank can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 47 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 specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain re
71. no limit to the length of time the vehicle may remain in AWD Engaging Front Gearcase 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 front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 39 FEATURES Instrument Cluster The instrument cluster measures distance in miles or kilometers as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Refer to page 31 for additional information CAUTION To prevent damage wash the ATV by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster Do not allow insect sprays to come into contact with the lens Miles Kilometers Toggle The display in the tripmeter od
72. ns 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 54 OPERATION Driving Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs 4 WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 55 OPERATION Turning Around on a Hill If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 56 OPERATION Turning Around on a Hill 1 2 3 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right unt
73. ometer and speedometer can be changed to display either kilometers or miles 1 2 40 To change modes press and release the mode button see page 31 as often as needed to reach the odometer mode In the odometer mode press and hold the mode button until the letters flash then release the button Press and release the button one more time When the display stops flashing the mode has been set FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster segments will light up for 3 seconds at start up 1 Gear Indicator As the shift lever is moved this indicates the gear the transmission is in 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 2 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 machine cannot be in reverse Mode 1 Odometer The odometer records the distance traveled by the Mode 2 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 NOTE In the Rider Information Center the trip meter display contains a decimal point but the
74. on Timing 100 H Wiring 100 H 1 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Clutches drive 100 H 1 1000 1600 Inspect clean replace worn and driven parts 1000 1600 Inspect replace as needed 200 H 2000 3200 Change every two years Adjust as needed Inspect periodically adjust when parts are replaced Adjust as needed p Perform these procedures more often for vehicles subjected to severe use Emission Related Service m Have an authorized Polaris dealer perform these services Front wheel 100 H 1 bearings Brake fluid Spark arrestor Idle speed Toe adjustment Headlight aim 67 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 64 Items not listed in the chart should be lubricated at the General Lubrication interval Lubrication Guide Key gt More often under severe use Polaris Premium All Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special e Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging m J wa Engine Oil See page 69 Add to proper level on dip stick See page 70 Brake Fluid DOT 3 Only Maintain level between fill lines See page 77 Transmission Oil Polaris P
75. or scratches MAINTENANCE AND LUBRICATION Engine Oil Oil Change 11 12 13 14 15 16 17 18 19 20 21 22 72 Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it Clean the filter sealing area on the engine Lubricate the filter o ring Check to make sure the o ring is in good condition Install the new oil filter After the filter contacts the engine surface turn it 1 2 turn by hand Remove the dipstick Add the recommended oil See page 69 Reinstall the dipstick Start the engine Allow it to idle E for two minutes Turn the engine off Check for oil leaks Check the oil level Add oil as needed to bring the level between the minimum and maximum marks Do not overfill Discard used oil and filter properly MAINTENANCE AND LUBRICATION Transmission Oil 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 Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64 Maintain the oil level at the bottom of the fill plug ho
76. p of the master cylinder A dark eye 2 indicates a full fluid level A clear eye 3 indicates a low fluid level Add the recommended fluid as needed Do not overfill Master Cylinder Foot Brake The reservoir 4 is located on 4 the right side of the ATV Maintain the fluid level MAX between the MIN and p MAX marks Do not overfill IY 78 MAINTENANCE AND LUBRICATION 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 Perform the following checks to keep the brake systems in good operating condition Check more often if brakes are used heavily during normal operation 1 2 Check the brake system for fluid leaks Check the brakes for excessive travel or spongy feel Check the friction pads for wear damage and looseness Replace pads when the friction material is worn to 03 8 mm Check the security and surface condition of the disc 03 8 mm 79 MAINTENANCE AND LUBRICATION 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 Toe Alignment 4 amp WARNING Severe injury or death can result from improper toe alignment a
77. park plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color 4 amp WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled 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 carburetion adjustments 90 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 1 Remove the left side panel See page 86 2 Remove the spark plug cap 3 Using the special wrench provided in the tool pouch rotate the spark plug 1 1 counterclockwise to remove 4 Inspect the electrodes for wear and carbon buildup Replace worn or NEN amp fouled plugs Verify that the gap is at specification be
78. park plug cap and install the cap onto the plug 4 Tum the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil Alternative to Using Fogging Oil If you choose not to use Polaris Fogging Oil perform the following procedure 1 Treat the fuel system with Polaris Carbon Clean following the instructions on the can Run the engine for several minutes so the Carbon Clean reaches the carburetor Turn the engine off 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 approximately two ounces of recommended oil into the cylinder 4 Reinstall the spark plug and torque to 18 ft Ibs 24 Nm 5 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 6 Turn the engine over several times to ensure coverage of piston rings cylinder walls and crankshaft bearings 7 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops 105 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate Follow lubrication guidelines in the Maintenance Section of the service or owner s manual to completely grease
79. r disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 100 MAINTENANCE AND LUBRICATION Battery Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a YUASA activated sealed battery Read all instructions before proceeding with the installation of this battery The YUASA activated sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing to 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 101 MAINTENANCE AND LUBRICATION Battery Battery Charging Sealed Battery For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery 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 rechargin
80. r 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 rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend 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 requirements 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 124 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION 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 ques tions This policy does not apply to vehicles registered to government of
81. remium AGL See page 73 Synthetic Gearcase Lube Front Demand Drive Unit Premium Demand Drive See page 75 Front Gearcase Hub Fluid Front Prop Shaft Yoke Grease Grease fittings 3 pumps Fig 1 maximum Steering Post Bushing Grease Grease fitting 8 pumps Fig 2 maximum Lower Control Arm Rear Grease Grease fittings 3 pumps Fig 3 maximum Bearing Carrier Grease Grease fittings 3 pumps Fig 4 maximum Fig 1 68 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64 Always change the oil filter whenever changing oil See page 112 for the part numbers of Polaris products Performance Synthetic 4 Stroke PS 4 Oil Polaris recommends the use of Performance Synthetic 4 Stroke PS 4 0W50 oil for this engine PS 4 is a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection Oil may need to be changed more frequently if Polaris oil is not used Always use 0W50 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 Engine Oil Specifications Performance Synthetic 4 Stroke 2 dts 14 ft Ibs PS 4 0W50 1 91 19 Nm 69 M
82. riodic Maintenance Chart beginning on page 66 Maintain the oil level even with the bottom of the fill hole threads 1 The fill plug 2 is located on the right side of the gearcase The drain plug 3 is located on the bottom right side of the gearcase Use the recommended oil Use of other oils may result in improper operation of components See page 112 for the part numbers of Polaris products 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 an 8mm Allen wrench 5 Check the oil level 6 Add the recommended oil as needed 7 Reinstall the fill plug Torque to specification 75 MAINTENANCE AND LUBRICATION Front Gearcase Oil Oil Change 1 Position the vehicle on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use an 8mm Allen wrench 5 Remove the drain plug Use an 11mm wrench 6 Drain the fluid into a drain pan Dispose of oil properly 7 Clean and reinstall the drain plug Torque to specification See page 75 8 Add the recommended oil See page 75 9 Reinstall the fill plug Torque to specification See page 75 10 Check for leaks 76 MAINTENANCE AND LUBRICATION Brakes Brake Fluid Check brake fluid levels for both brake systems before each use of the vehicle Always
83. rol 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 attempting to turn at faster speeds Never turn at excessive speed SAFETY Operator Safety 4 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 Practice on smaller hills before attempting large hills 4 WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD E Always follow proper ES SS procedures for climbing hills as described in the owner s manual ok Always check the terrain c carefully before ascending any hill Never operate the ATV on hills steeper than 25 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 a sharp drop or another vehicle or person could be on the other side of the hill 23 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly d
84. s Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less See illustration 1 8 3 cm Front Wheel Hub Tightening Front wheel bearing tightness and spindle A nut retention are critical component operations All service must be performed by your authorized Polaris dealer 81 MAINTENANCE AND LUBRICATION Wheel Replacement 4 amp WARNING 82 Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer Position the vehicle on a level surface o Place the transmission in Q gear Lock the parking brake Loosen the wheel nuts slightly Safely place jackstands under the vehicle Raise the wheel slightly off the ground Remove the wheel nuts and remove the wheel MAINTENANCE AND LUBRICATION Wheel Replacement 7 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 8 Install the wheel nuts finger tight 9 Lower the vehicle to the ground 10 Torque the wheel nuts to specification awe Wheel Nut Torque Specifications Chec
85. s present in fuel Fuel valve is turned off Old or non recommended fuel Fouled or defective spark plug s No spark to spark plug Crankcase filled with water or fuel Overuse of choke Clogged fuel filter Low battery voltage Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed 113 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 114 Kinked or plugged fuel vent line Inspect and replace TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical
86. t of the vehicle ON For normal operation E 2 OFF For vehicle storage and when transporting rN Refuel when the instrument gauge indicates a low fuel level ON OFF 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 36 CONTROLS Recoil Starter If the battery has been drained or damaged and cannot start the engine use of the recoil starter 1 will allow vehicle operation until repairs can be made The recoil starter is located on the right side of the machine 1 Position the vehicle on a level surface Lock the parking brake 2 Place the transmission in neutral 3 Make sure the engine stop switch is set to RUN and the main key switch is in the ON position NOTE If the engine is cold use the choke as outlined on page 46 4 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke will be a compression stroke and will make the rope harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 5 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 6 Repeat steps 4 5 if necessary CAUTION Exten
87. test product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication 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 2006 Hawkeye Owner s Manual P N 9920202 2 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS 5 SAFETY ka arce yir a EE a 6 CONTROLS EXE 31 FEATURES S 39 OPERATION 1 5 222353292 x429 nr n RR 42 EMISSION CONTROL SYSTEMS 63 MAINTENANCE AND LUBRICATION 64 ADJUSTMENTS 108 POLARIS PRODUCTS 112 TROUBLESHOOTING 113 SPECIFICATIONS 116 WARRANTY EE 122 MAINTENANCE LOG 127 INDEX A CERE sees 130 VEHICLE IDENTIFICATION NUMBERS Record your ATV s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both
88. 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 127 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 Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase 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 64 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key p Perform these procedures more frequently for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions m Have an authorized Polaris dealer perform t
89. ting 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 4 WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 19 SAFETY Operator Safety 4 WARNING 20 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 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 in the owner s manual SAFETY Operator Safety 4 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
90. ube NOTE The vent tube must be free of obstructions and securely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte which can cause severe burns First connect and tighten the red positive cable Second connect and tighten the black negative cable Attach the battery hold down strap Verify that cables are properly routed SUUS dee ona NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance 99 MAINTENANCE AND LUBRICATION Battery Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool dry place and tested monthly Before reusing take the battery to your dealer for testing and recharging Power plug leads may need to be bent down so that the battery cover can be installed Replenishing Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that are harmful to a battery 4 WARNING Improperly connecting o

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