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Polaris 300 2X4 Offroad Vehicle User Manual

1. 60 Oil Recommendations 59 Operator Safety 5 13 Override Switch 34 P P rking Brake so on ed evidences 39 Parking on an Incline 30 Periodic Maintenance Chart 53 57 Polaris Product List 107 122 P Polishing the Vehicle 97 Position Light Lamp 80 Pre Ride Checklist 49 PYT Beak IN 35 4 ck saakew ead 48 PVE In ois em ees Boos 88 89 PYT SYStCi 6s tee cea a ced 88 89 R Recoil Housing dd dak 4 aed 82 Recoil Sret or es aoc ea gees ea 43 Reverse Operation 31 Reverse Override Switch 34 Rider Information Center 46 Riding Gear ask ask det Sah eke 16 17 S Safety Decals No Passenger Warning 15 Age 16 Ale idctiwiuad cee 14 General Alert 14 Hill Operation Alert 14 Rack Warning Front Rear 15 Reverse Override Alert 15 Tire Pressure Load Alert 15 Safety Training 954 nea cna shoe ad ws 6 Severe USSG AET ca hnce ee oe d2 53 Side Panel Removal 13 edale atiri eTe S eee 24 Signal Words nnana aana 5 Spark Arrestor n a onnan 87 Spark Arrestor Requirements 52 Spark Plugs esio k EEEN 83 84 Spring Adjustments 103 Starting the Engine 50 51 Steering Assembly 13 Steering Lockek aarne eet A a 40 SLOP SWItCh 3 2 2 0 aui oad E rane 35 IOLA Ss 35 3 TR 96 101 Swi
2. a A SC LEZ SCLZZZZZZZZ ZZVZZ AN SN Wi 81 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet conditions Drain the housing before storing the vehicle Make sure the housing is completely dry before reinstalling the drain plug 1 Place the transmission in PARK 2 Stop the engine 3 Remove the drain screw on the bottom of the recoil housing 4 Allow the housing to drain com pletely 5 Reinstall the drain screw NOTE Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crank case drain is opened 82 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 112 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification Plug Condition Torque Specification New Spark Plug 12 15 N m Previously Installed Spark Plug 23 27 N m 1 Remove the left side panel s See page 75 r 2 Remove the spark plug cap Q 3 Use the spark plug wrench to remove the spark plug Turn the plug counterclockwise to remove it A 4 Inspect the electrodes for E wear and carbon buildup Replace worn or fouled lt SS plugs Verify that the gap is at specification before installation 5 Reinstall the spark plug Torque to specification 6 Reinstall the spark plug cap D5 4
3. A Never allow anyone under 16 years of age to operate this vehicle Never carry a passenger The purpose of the long seat is to allow the operator to shift position SAFETY Operator Safety Always wear an approved helmet that fits properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants Never consume alcohol or drugs before or while operating a Quadricycle A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience A Never attempt jumps or other stunts SAFETY Operator Safety Always inspect your Quadricycle before each use to verify that it s in safe operating condition Follow the inspection and maintenance procedures outlined in this manual See page 49 Keep both hands on the handlebars Keep your feet on the footrests Always travel slowly when operating on unfamiliar terrain Use extra caution Use caution when operating on rough slippery or loose terrain A Always follow the procedures outlined in this manual for turning See page 19 Never turn sharply at excessive speeds which can lead to vehicle overturn SAFETY Operator Safety A lf a Quadricycle has been involved in an accident always have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not limited to brake throttle and steerin
4. POLARIS The Way Out 2007 Quadricycle Owner s Manual for Maintenance and Safety Hawkeye 2X4 Hawkeye 4X4 Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Before you operate this vehicle read the owner s manual Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehiculo lea el Manual del Propietario Lire le manuel du propri taire avant d utiliser ce v hicule Prima di usare il veicolo leggete il manuale di istruzioni Lue aina k ytt ohjekirja ennen t m n ajoneuvon k ytt Antes de utilizar este ve culo leia o manual do propriet rio Innan du k r detta fordon l s handboken CD CED CF CID FID CP CS at Ce For your nearest Polaris dealer 3 POLARIS cai 1 800 POLARIS f The Way Out or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 U S A Phone 1 763 417 8650 Fax 1 763 542 0599 Part No 9920788 Rev 01 Printed in U S A WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e Quadricycles e RANGER utility vehicles e Victory motorcycles Always follow the instructions and recommendations in this ma
5. 00 38 Brake Hand 38 Brake Parking 39 Brakcueht 250 we hee TETEA 81 ITA CSickn att Sho Aen oe chk eck 73 Break In Period 48 Breather Filer ereere ee oie 2 78 C CarDureton sses diaus r eed oka 105 Carburetor Adjustment 105 RI Oia ets aaae aa 32 33 CHO er ashe sure E dares ANAT a7 Chrome Wheel Care sce ese ate 98 Cleaning and Storage 96 101 CIOMMMNO 43 2 0 e tase ha eee ses 17 Clutching Chart 2X4 113 Clutching Chart 4X4 115 Cold Weather Operation 51 Corrosion Removal Chrome 98 D Demand Drive Fluid 67 69 Drive Belt Wear Burn 108 Drivetrain Break In 48 Driving Downhill 25 Driving in Reverse 31 INDEX D Driving on a Sidehill 24 Driving on Slippery Surfaces 20 Driving Over Obstacles 21 Driving Procedures 18 Driving Safely 18 33 Driving Through Water 28 29 Driving Uphill 22 23 E Electromagnetic Interference 52 Electronic Throttle Control 37 Engine Break In 48 Engine Fogging 100 Engine Idle RPM Adjustment 105 Pie Te Oll to serine le ee ae 59 60 Equipment Modifications 6 Exhaust Emission Control System 52 Eye Protection 17 F Fluid Brakai isad ekaa 70 72 Demand Drive 67
6. off Q 3 Remove the spark i OFF 4 Drain any water found in the air box 5 Loosen the carburetor drain screw and drain the carburetor 85 MAINTENANCE Vehicle Immersion 6 10 11 12 Turn the ignition key past the POSITION LIGHTS position to engage the starter Engage the starter for only 2 3 seconds Tighten the carburetor drain screw o Dry the spark plug S Reinstall the plug or SL install a new plug S Torque to specification ON Attempt to start the engine If necessary repeat the drying procedure Turn the fuel valve on Have the vehicle serviced by your dealer promptly whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 86 88 for drying out the PVT MAINTENANCE Spark Arrestor Occasionally the spark arrestor may accumulate carbon which can restrict the exhaust if left unattended Purge the spark arrestor A WARNING Allow components to cool sufficiently before servicing The exhaust system can get extremely hot Never run the engine in an enclosed area or indoors Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging 1 Position the vehicle on a level surface 2 Place the t
7. 1 Remove the two screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell Rivets Rivets Y De at gs __ LELEL R 15 MAINTENANCE Tires Refer to the specifications section beginning on page 112 for recom mended tire type size and pressure A WARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident Maintain proper tire pressure as described on the decal on your vehicle and in the specifications section of the owner s manual Use only original equipment size and type when replacing tires Make sure the wheels are installed properly Replace tires when the tread depth measures 3 mm or less Tire Tread Depth Always replace tires 3 mm when tread depth is worn to 3 mm or less 7 CO XS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service Front Wheel Nuts 27 ft lbs 87 N m Rear Wheel Nuts 27 ft lbs 87 N m 76 MAINTENANCE Tires A WARNING Operating with improperly installed wheels will
8. 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys tems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 61 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Clean or replace the breather filter 4 Drain the sediment tube Recoil Housing 1 Drain the recoil housing See page 82 99 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 53 e Demand drive unit front gearcase e Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean See page 99 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 60 ml of engine oil into the cylinder 4 Reinstall the spark plug Torque to specification 5 Apply dielectric greas
9. Above 3000 Same main jet Remove 6 air box plugs Move jet needle clip to position 2 Clutching Chart Altitude Roller Number of Rollers Driven Clutch Meters Weight Spring 0 1500 13 g 5412988 a 7043228 1500 3000 10 g 5412986 a 7043228 3000 10 g 5412986 6 7043228 Remove two opposite rollers to maintain clutch balance 115 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediat
10. MAINTENANCE Hol I HO a UT cma Pe p z y s 73 MAINTENANCE Toe Alignment A WARNING Do not attempt to adjust alignment All steering adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 3 6 mm toe out 1 Place the handlebars in a straight ahead position 2 Place stands in front of the vehicle per pendicular to the rear tires 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim Rear measurement String Rear of Front Rim Front of a Front Rim J ZT AN S UZE af a CIEE f pane N White OU ll Stands should be 2 3 mm more than the front measurement NOTE 74 If you discover improper alignment see your Polaris dealer for service MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Side Panel Removal 1 Remove the seat 2 Grasp the top of the side panel and pull it outward to remove it Footwell Removal
11. drain plug is located on the bot tom right side of the gearcase Demand Drive Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Demand Drive Premium Demand Drive 148 ml 11 13 N m 11 13 N m Unit Hub Fluid 67 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Check 1 Position the vehicle on a level surface 2 Place the transmission in PARK ie DAL DN A S lt A lA Kay KY WAN y Fp A 5 g Q 3 Remove the fill plug Use an 8 mm Allen wrench 4 Check the fluid level 5 Add the recommended fluid as needed 6 Reinstall the fill plug 7 Torque to specification See page 67 68 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Change 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Use an 8 mm Allen wrench 4 Place a drain pan under the gearcase 5 Remove the drain plug Use an 11 mm wrench 6 Allow the oil to drain completely 7 Clean and reinstall the drain plug Torque to specification See page 67 8 Add the recommended fluid 9 Reinstall the fill plug Torque to specification 10 Check for leaks 11 Dispose of used oil properly 69 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride Always maintain brake fluid at the recommended level Do not overfill The brakes should feel firm when they r
12. 2 Place the transmission in PARK 3 Turn the fuel valve off Secure the fuel cap oil cap and seat OFF 5 Remove the key to prevent loss during transporting 6 Always tie the frame of the Quadricycle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets mh 4 l N AL A 2 m p N TIN IN SA 115 A Ne aR A AAPAN A A FTE NNN NER N CNE gt aril BY SS y OA Towing a Disabled Vehicle If towing the vehicle is necessary shift the transmission into neutral for better mobility and to prevent damage to the belt Always attach the tow rope to the frame of the Quadricycle 102 ADJUSTMENTS Spring Adjustments The front and rear shock absorber springs are adjustable Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension Always adjust both sides equally NOTE Accessory springs are available through your Polaris dealer Front Adjuster 103 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control Follow the adjustment procedures exactly or see your Polaris dealer for
13. 3 Be alert 4 Watch the trail 5 Avoid quick sharp turns NOTE To correct a rear wheel skid turn the handlebars in the same direction as the skid and shift body weight forward Severe damage to the drive train may occur if AWD is engaged while the wheels are spinning Engage AWD when the wheels have traction A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding 20 SAFETY Driving Safely Driving Over Obstacles 1 Always check for obstacles before operating in a new area Serious injury or death can result if your vehicle comes in contact with a hidden obstacle Be alert Watch the terrain Use extra caution E Never operate over large obstacles 4 Avoid hazards such as logs rocks and low branches A Always follow the procedures outlined in this manual for operating over obstacles 21 SAFETY Driving Safely Driving Uphill 25 Maximum Whenever traveling uphill follow these precautions Avoid steep hills 25 maximum Check the terrain carefully Avoid hills with excessively slippery or loose surfaces Shift your weight uphill Drive straight uphill Keep your feet on the footrests Drive at a steady rate of speed to avoid stalling OC NAWKRWN S Be alert Be prepared to take emergency action This may include dismounting quickly 9 Never open the throttle su
14. 4 17 cm result in serious damage to the vehicle and will void your warranty Never install a hitch longer than 6 3 4 17 cm Never install automotive accessories on your Polaris Quadricycle Always install Polaris approved or equivalent accessories designed for Quadricycle use 33 FEATURES AND CONTROLS Switches Mode Reverse C Override Switch C n S Main Key i Nig Switch Ba a Ep EH J O lt All Wheel Drive Switch Headlight Switch Engine Stop Switch Mode Reverse Override Switch Press the switch to toggle through the speedometer display modes except in reverse See page 45 To gain additional power while operating in reverse press the override switch before opening the throttle This will cancel the reverse speed limit function NOTE The override switch also allows activation of All Wheel Drive in reverse if the AWD switch is on A WARNING Activating the override switch with the throttle open and while operating in reverse can cause loss of control Do not activate the override switch while the throttle is open 34 FEATURES AND CONTROLS Switches Main Key Switch Ge End all electrical power to the vehicle LIGHTS ON position turns the headlights on O Start the engine The headlights are not on in this position D 0E After starting the engine release the key switch to the POSITION LIGHTS ON position A WARNING Do not attach a large
15. 48 TROUBLESHOOTING Engine Does Not Rotate Possible Cause Solution Low battery voltage Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Rotates Fails to Start Possible Cause Solution Out of fuel Refuel Clogged fuel valve or filter Inspect and clean or replace Water or fuel in crankcase Immediately see your Polaris dealer Clogged fuel filter Replace the filter Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel e o Loose ignition connections See your dealer 109 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug s Inspect clean and or replace spark plug s Possible Lean Fuel Cause Solution Possible Rich Fuel Cause Solution Overuse of choke Inspect clean and or replace spark plugs Fuel is very high octane Replace with low
16. 69 Transmission 64 66 Foot Brake aside ci tagnareeds 38 Footwell Removal 73 Front Gearcase 67 69 Pure Fillore espen penan dat aad 4 Ruel Satety yc 2 4i eee tats 47 Fuel Tank Capes tviaten cinta ures 41 Fuel Valves s 6 4 bier dte Mop peoi 41 G Gear SClEClIOla hic anaE SEER 42 RTO CS rte laste Sh to ee Ble ls 17 H Hand Braken siose Shoah eas 38 Handlebar Adjustment 104 Hauling Cargo 32 33 Hazard Warning Switch 36 Headlight Beam Adjustment 79 Headlight Lamp 80 Heei iia te weak ark aor atontag 16 Horn Swit h xu 22 enc thaas sritis 36 121 INDEX Idle RPM Adjustment 105 IMMCPSION 4 a wee S 85 86 Instrument Cluster 45 46 J Jetting Chart 2X4 113 Jetting Chart 4X4 115 K KOY SWIC Hewes otal ae ae 35 KeT Ue euick nh oe et at beet 26 27 L Light Switch 35 Lights Headlight Beam Adjustment 79 Headlight Lamp 80 Position Light Lamp 80 Taillight Brakelight 81 Turn Signal Lamp 81 Lubrication Guide 58 M Maintenance Chart 53 57 MIOS eiui aaa bate EEREN 37 Mod SWALC I chr iat eee ok ate 34 Modifications 0085 6 N Noise Emission Control System 52 O Oil Poineae rerea Cerne ene ee 59 60 Transmission 64 66 Oil and Filter Change 61 63 Oil Level Engine
17. MAINTENANCE Spark Plugs Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color Normal Spark Plug The normal insulator tip 1s tan or 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 throttle body carburetor adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil con sumption improper use of the choke or incorrect throttle body carbure tor adjustments 84 MAINTENANCE Vehicle Immersion CAUTION If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If your vehicle has been totally submerged in water and it s impossible to have it serviced before further operation perform the following procedure 1 Move the vehicle out of the water 2 Turn the fuel valve
18. and release the button once When the display stops flashing the mode has been set 45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All seg ments will light up for 3 seconds at start up 1 Gear Indicator This indicator displays gear shifter position N Neutral Green R Reverse Amber 2 Engine Hour Display Indicator 3 Speedometer Odometer Tripmeter Hour Meter Modes Use the reverse override mode 2 4 button to toggle through the 3 standard modes NOTE If using the mode button to program the rider information center or to toggle through the options the transmission cannot be in reverse Odometer The odometer records the distance traveled by the vehicle Trip Meter The trip meter records the distance traveled by the vehicle on each trip if it s reset before each trip To reset the trip meter toggle to the trip meter mode Press and hold the mode button until the display changes to 0 In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter This mode logs the total hours the engine has been in operation 46 OPERATION Fuel Safety A WARNING Gasoline is highly flammable and explosive under certain conditions Use extreme caution whenever handling gasoline Refuel with the engine stopped Refuel outdoors or in
19. both front and rear brakes Squeeze the brake lever toward the handlebar to apply the all wheel brakes If the rear wheels begin to skid or slide while using this brake reduce lever pressure A WARNING Aggressively applying the brakes when backing down a hill may cause rear tipover Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control Read this owner s manual and understand the operation of all brake systems on this vehicle Always use caution whenever applying the brakes 38 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1 Place the transmission in PARK 2 Squeeze the brake lever toward the handlebar 3 Push the parking brake lock forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever A WARNING Operating the Quadricycle while the parking brake is engaged could result in an accident and serious injury or death Always release the parking brake lock before operating 39 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle 1 Turn the handlebars to the full left position 2 Insert the steering lock key and turn it clockwise 3 Remove the key 4 Reverse the procedure to unlock the steering NOTE Place the steering lock keys in a safe place The lock must be replaced if th
20. clothing to reduce the chance of injury L Eye Protection Helmet Long Sleeves Gloves Long Pants Helmet Always wear a helmet that meets or exceeds established safety stan dards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label 16 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection SAFETY Driving Safely Driving Procedures PS ey a oe a 18 Sit upright Keep your feet on the footrests Keep both hands
21. power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 96 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items e Wheel bearings e Transmission seals e Brakes e Cab and body panels e Labels and decals NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 97 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome
22. service 1 Loosen the four handlebar bolts 2 Adjust the handlebar to the desired height NOTE Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 3 Torque the front two bolts to 14 17 N m then torque the rear two bolts A gap of up to 3 mm will remain at the rear bolts Handlebar Bolts 104 ADJUSTMENTS Carburetor Your Polaris Quadricycle is calibrated at the factory for optimal perfor mance at altitudes ranging from zero to 1800 meters and temperatures of 4 degrees C or higher Above 1800 meters the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 300 meter 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 1800 meters Jetting is required only when operating below 4 degrees C at 1800 meters and lower NOTE Operating the engine with improper jetting can cause poor perfor mance overheating or engine damage See your Polaris dealer for more information about jetting Carburetor Engine Idle RPM Adjustment 1 Place the transmission in PARK H 2 Start the engine Allow it to warm up for approximately five minutes 3 Adjust the screw inward clockwise to raise RPM Adjust the screw outwa
23. the starting procedures on page 50 cranking the engine with the recoil starter instead of the main key switch 1 Grasp the recoil starter rope handle tightly 2 Pull slightly until the starter mechanism engages 3 Pull the rope abruptly to start the engine CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops lf 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 43 FEATURES AND CONTROLS All Wheel Drive AWD System 4X4 Models The AWD switch may be turned on or off while the vehicle is moving AWD will not engage until engine speed is below 3100 RPM AWD remains engaged until the switch is turned off There is no limit to the length of time the vehicle may remain in AWD If the switch is turned off while the demand drive unit is engaged it will not disengage until the rear wheels regain traction Engage AWD before getting into situations where maximum traction is needed If the rear wheels are spinning release the throttle before switching to AWD NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 34 CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Alwa
24. CE Brake Fluid Hand Brake Master Cylinder The master cylinder is located on the left handle bar Maintain the fluid level 6 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 win dow eye on the top of the master cylinder NOTE The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed Do not overfill 71 MAINTENANCE Brake Fluid Foot Brake The brake fluid reservoir is located near the foot brake Maintain the fluid level between the minimum and maximum marks Do not overfill J2 Brakes The front and rear brakes are hydraulic disc brakes activated by apply ing either the hand brake or the foot brake Both brake systems are self adjusting Brake Inspections Perform the following checks to keep the brake systems in good operat ing condition Check more often 1f brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 70 2 Check the brake systems regu larly for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the fric tion material is worn to 8 mm 5 Check the security and surface condition of the disc
25. H 1000 1600 Inspect adjust Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years TOO 1000 7600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe Spark plug 100 H 1000 1600 Inspect replace as needed Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc 56 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichever comes first aie aaa km km ke Shae drive Kag kaai S 1600 H REN clean replace worn ke Shae on parts Front wheel 100 hi 1000 1600 Inspect replace as needed bearings E Brake Brake fluid 200 H H 2000 3200 a Change every two years two years DR Spark arrestor 300 Ea o Clean out idle Idlespeed M A as needed n EET periodically adjust when parts are replaced Brakes Inspect daily adjust as needed M a E gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 57 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Items not listed in the chart should be lubricated at the General Lubrication interval Engine Oil Polaris Premium 4 Synthetic See p
26. NOTE Cables should be safely tucked away at the front and rear of the bat tery 92 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 107 for the part numbers of Polaris products Battery Fluid Conventional Battery Check the battery fluid level often Maintain the fluid level rea Upper between the upper and lower ae Mark level marks Add only distilled water Tap water contains minerals that are harmful to a battery es YBI4 r 4011359 WYUASA MFD FOR YUASA BATTERT INC READING PA 19605 YB14 B2 M224B2 MADE IN TAIWA 93 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 91 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed t
27. a well ventilated area Never fill a fuel container while it s on the vehicle Static electricity between the rack and container could cause a spark Do not smoke or allow open flames or sparks in or near the area where 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 Turn the fuel valve off whenever the vehicle is stored or parked 47 OPERATION Break In Period The break in period for your new Polaris Quadricycle 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 will increase the life and perfor mance of your Quadricycle more than following the procedures for a proper break in Careful treatment of a new engine and drive compo nents will result in more efficient performance and longer life for these components Do not operate at full throttle or high speeds for extended periods during the first three hours of use Install the accessory oil cooler when the following conditions exist e The vehicle will be used for towing heavy loads e The vehicle will be used for dragging ground surfaces or performing similar activities e The vehicle is normally operated when the air temperature is above 100 F 38 C Engine and Drivetrain Break in 1 Fill the fuel tank with the re
28. able check often if operating in wet conditions Brake pad wear Monthly 100 160 Inspect periodically Battery Battery 20 20H Monthly AREE terminals clean test Demand drive unit 25 ELA Monthly _ Inspect level change yearly oil front gearcase Transmission oil oil 25 25H Monthly Inspect level change yearly beac lil breather 25 Boll Race a Inspect clean if needed filter if equipped gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 33 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Carburetor float 50 H 500 800 Drain bowl periodically and bowl prior to storage Throttle Cable 50 H 500 800 Inspect adjust lubricate ETC Switch replace if necessary Choke cable 50 H 500 800 Inspect adjust lubricate replace if necessary Carburetor air 50 H 500 800 Inspect duct for proper seal intake ducts flange ing air leaks Drive belt 50 H 500 800 Inspect adjust replace as neede ded Engine oil change 100 H 1000 1600 Perform a break in oil change at 20 hours Oil filter change 100 H 1000 1600 Replace with oil change Oil tank vent hose 100 H 1000 1600 Inspect routing condition if equipped 100
29. affect vehicle handling and could cause an accident resulting in serious injury or death Always use original equipment size and type when replacing tires Install wheels properly Wheel Removal Installation 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Loosen the wheel nuts slightly Place a suitable stand under the footrest frame to raise the wheel slightly off the ground 5 Remove the wheel nuts 6 Remove the wheel 7 Place the wheel on the hub 8 Install the wheel nuts finger tight 9 Lower the vehicle to the ground 10 Torque the wheel nuts to specification See page 76 71 MAINTENANCE Air Filter Breather Filter Always clean and replace the air and breather filters at the intervals out lined in the Periodic Maintenance Chart beginning on page 53 1 Position the vehicle on a level H surface 4 2 Place the transmission in PARK R 3 Remove the seat Sleeve Release the air box p Clips cover clips and remove the air box cover 5 Remove the air filter 6 Remove the sleeve from the filter 7 Wash the sleeve in soapy water then rinse and let dry 8 Remove the breather fil ter Wash the breather filter in soapy water then rinse and let dry 9 Reinstall the breather filter CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for
30. after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 10 Ifthe engine slows or stops after starting move the choke knob FULL ON Heal to HALF ON Vary engine RPM slightly with the throttle HALF ON al When the engine idles smoothly push the choke all the OFF K way 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 Internal engine condensation increases as outside temperatures decrease If the vehicle is used year round check the oil level fre quently A rising oil level could indicate condensation in the bottom of the oil tank which can lead to engine damage Any condensation must be drained Always operate the engine long enough to reach operating temperature which reduces condensation See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in cold weather 51 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with governmental noise level requirements Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on road and off road operation It 1s required that this spark arrestor remain installed and functional when the vehicle is operated Exhaus
31. age 59 OW 50 Brake Fluid DOT 4 Only See page 70 Transmission Oil Polaris AGL Synthetic See page 64 Gearcase Lube Front Demand Drive Unit Premium Demand Drive Hub See page 67 Front Gearcase Fluid Front Prop Shaft Yoke Control Arm front and rear Lube periods of storage or after pres Bearing Carrier sure washing or submerging Transmission upper pivot point Grease fittings 3 pumps maxi Polaris Premium U Joint mum every 800 km before long Front Prop Shaft Yoke Transmission Upper Pivot Point Bearing Carrier 58 MAINTENANCE Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Always change the oil filter whenever changing oil Change the oil more often if the vehicle is routinely subjected to e operation in dusty or wet conditions e operation when air temperature is below 12 C e short trips at 12 to 1 C engine fails to reach operating tempera ture Polaris recommends the use of Performance Synthetic 4 Stroke PS 4 OW 50 oil for this engine PS 4 is a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication per formance and protection Oil may need to be changed more frequently if Polaris oil is not used Always use 0W 50 oil Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brand
32. commended fuel See page 41 2 Check the oil level See page 60 Add oil if necessary 3 Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Drive slowly Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 49 6 Pull only light loads 7 Change the oil and filter at one month PVT Break in Clutches Belt Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggres sive acceleration and high speed operation during the break in period 48 OPERATION Pre Ride Checklist Foot brake brake Ensure proper operation 38 Hand a travel Ensure proper operation Brake fluid Ensure properlevel Ensure properlevel level Co aaa unos recone 08 Steering Ensweteeoperion Frame nuts bots fasteners Inspect ensure tightness Fuel and oil Ensure proper levels T Throttle Ensure proper operation Ne a Headlamp Check operation apply Polaris D tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 16 protective clothing 49 OPERATION Starting the Engine A WARNING Engine exhaust contains poisonous carbon monoxide and can caus
33. ddenly or make sudden gear changes 10 Never go over the top of a hill at high speed 22 SAFETY Driving Safely Driving Uphill If all forward speed is lost Keep your weight uphill If the vehicle begins rolling downhill never apply engine power Never apply the brakes aggressively while rolling backwards Apply the brakes gradually When fully stopped lock the hydraulic parking brake See page 39 Dismount on the uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around using the K Turn See page 26 A Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 25 A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 23 SAFETY Driving Safely Driving on a Sidehill Sidehilling Avoid crossing the side of a hill sidehilling if possible If sidehilling 1s necessary follow these precautions Slow down Avoid hills with excessively slippery or loose surfaces Shift your weight uphill Avoid crossing the sides of steep hills Keep your feet on the footrests Steer slightly into the hill NOTE Ifthe vehicle begins to tip quickly turn the front wheels downhill if possible or dismount on the uphill side immediately A Always follow the procedures outlined in this manual for crossing the side of a hill Never a
34. de switch is used Do not operate at full throttle Apply just enough throttle to maintain the desired speed A Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage A Always follow the procedures outlined in this manual for driving in reverse 31 SAFETY Driving Safely Hauling Cargo A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo Read and understand the load distribution warnings listed on the vehicle warning labels Never exceed the stated load capacity for this vehicle REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING Use extreme caution when applying brakes Avoid situations that require backing downhill When operating over rough or hilly terrain reduce speed cargo and towed load to maintain stable driving conditions DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition Reduce load weight when cargo is high Secure off centered loads that cannot be centered and operate with extra caution CARRYING A LOAD on only one rack may cause the veh
35. dricycle Maintain the proper tire pressure Never modify a Quadricycle through improper installation or use of accessories Never exceed the stated load capacity for your Quadricycle 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 12 SAFETY Operator Safety A Never operate the Quadricycle on a frozen body of water Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control accident and or injury Avoid sudden turns or swift movement of the handlebars A Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting a A Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system For more information about Quadricycle safety call Polaris at 1 800 342 3764 13 SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection Read and follow the instructions on each decal carefully If a 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 The following pages repeat
36. e applied Spongy or weak brakes may indicate a fluid leak or low fluid level A low fluid level may also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongy or weak brakes See your dealer for ser vice A WARNING Operating the Quadricycle with a spongy brake can result in loss of braking which could cause an accident Never operate the Quadricycle with spongy feeling brakes If the fluid level is low add DOT 4 brake fluid only See page 107 for the part numbers of Polaris products A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A 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 70 MAINTENAN
37. e keys are lost 40 FEATURES AND CONTROLS Fuel Tank Cap Fuel Tank Remove the fuel tank cap to Cap ah add fuel to the fuel tank Use IAN either leaded or unleaded gaso line with a minimum pump octane of 87 Do not use E 85 fuel Fuel Valve The fuel valve is located on the bottom of the fuel tank Access the fuel valve through the right front wheel well H dha ON For normal operation OFF For vehicle storage and when transporting Refuel when the instrument gauge indicates a low fuel OFF level Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 41 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle H High Gear N Neutral R Reverse P Park Whenever the vehicle is left unattended always place the transmission in PARK The transmission is locked when it s in PARK Gear Selector CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage Stop the vehicle release the throttle and move the shift lever to the desired gear See your dealer if you experience any shifting problems 42 FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine use the recoil starter Handle Recoil Starter Follow
38. e loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating 1 Position the vehicle ona level surface 2 Place the transmission in PARK 3 Turn the fuel valve on 4 Sit on the vehicle NOTE Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to ON become wet fouled 5 Ifthe engine is cold pull the choke knob out until it stops NOTE Make sure the choke is off during operation Excess fuel washing into the engine oil will increase wear on engine components 6 Move the engine stop switch to RUN NOTE Do not press the throt tle while starting the engine 50 OPERATION Starting the Engine 7 Turn the ignition key past the POSITION LIGHTS ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine Starts 8 Ifthe engine does not start release the starter and wait five seconds 9 Repeat steps 7 and 8 until the engine starts NOTE Ifa warm engine has cooled and does not readily start intermittent use of the choke HALF ON 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
39. e materi als or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 117 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris Quadricycles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANS PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris sugge
40. e of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 90 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Place the transmission in PARK 2 Open the front cover 3 Disconnect the battery hold down strap PN 4 On conven
41. e to the inside of the spark plug cap Reinstall the cap 6 Turn the engine over several times using the recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 7 If Polaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline 100 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 53 Battery Storage See pages 93 94 for storage and charging procedures Storage Area Covers 1 Set the tire pressure and safely support the vehicle with the tires slightly off the ground Be sure the storage area is well ventilated 3 Cover the vehicle with a genuine Polaris cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your vehicle Always install accessories that are approved for Quadricycle use Please see your Polaris dealer 101 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Stop the engine
42. e under 16 years of age Restrictions This vehicle is approved for OFF ROAD TOWING ONLY Operating a Quadricycle trailer combination on public roads is prohibited Equipment Modifications The warranty on your Polaris Quadricycle may be terminated if any equipment has been added or if any modifications have been made that increase speed or power NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers and large racks may change vehicle han dling Use only Polaris approved accessories Know their function and effect on the vehicle SAFETY Operator Safety A WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual A Read and understand all warnings cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle Read and understand all warnings cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle Never operate a Quadricycle without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris Quadricycle dealer or call Polaris at 1 800 342 3764 Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels and have completed a certified safety training course
43. ely NO WAR RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 116 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any Quadricycle that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any dam ages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the Quadricycle The exclusive remedy for breach of this war ranty shall be at Polaris exclusive option repair or replacement of any defectiv
44. ems 52 Maintenance 0 00 eee 53 AGIUSIMCMS siisi were wean ees 103 Polaris ProduClSin ei cance veweteddteadw es 107 Troubleshooting 0 0000eeeeeee 108 SPECHICAHONS 4 0 42 225 buat o dae ee ede 112 Warranty oc 2220 628c h02200e000 2 200068 116 Maintenance Log 0000 ee eeaee 119 INGO rarena Bar ete eee a we ee ae 121 KNOW YOUR VEHICLE As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable informa tion about all aspects of your vehicle including safe operating proce dures Ride responsibly Know all laws and regulations concerning the opera tion of this vehicle in your area Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Engine Serial Number Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become fam
45. er and allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 26 SAFETY Driving Safely Turning Around on a Hill K Turn 8 Lock the hydraulic parking brake 9 Remount from the uphill side Keep your weight uphill 10 Apply the foot brake 11 With the transmission still in forward start the engine 12 Squeeze and release the brake lever to release the parking brake 13 Release the foot brake and drive slowly downhill Control speed with either the hand or foot brake until the vehicle is on level ground A Always follow the procedures outlined in this manual for climbing hills See page 22 Always follow the procedures outlined in this manual for crossing the side of a hill See page 24 27 SAFETY Driving Safely Driving Through Water Maximum Depth Follow these procedures when driving through water l 2 28 Check water depth and current before crossing Avoid operating in water deeper than the bottom of the footrests If it s unavoidable travel slowly balance your weight carefully and avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns stops or throttle changes Choose a crossing where both banks have gradual inclines Drive slowly Avoid rocks and obstacles Wet brakes may have reduced stopping ability Always test your brakes after leaving water If necessary apply them lightly several times to allow
46. er octane fuel Incorrect jetting See See your dealer See your dealer Stopping starting without adequate Allow engine to warm up before operat warm up ing and or stopping Clogged air filter Inspect and clean or replace 110 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Fouled or defective spark plug s Inspect clean and or replace spark plug s Loose ignition connections Recharge the battery to 12 8 VDC Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean engine exterior see your Polaris dealer Engine Overheating Possible Cause Solution Towing dragging heavy loads Install the accessory oil cooler if the vehicle will be used for towing heavy loads dragging ground surfaces or performing similar activities Operating in excessive heat Install the accessory oil cooler if the vehicle is normally operated when the air temperature is above 38 C 111 SPECIFICATIONS Hawkeye 2X4 International Hitch Tongue Weight Capacity 34 kg Rear rack capacity and tongue weight not to exceed 45 kg Hitch Towing Rating 340 2 kg Capacity Compression Ratio Ignition System DC CDI DCCDI S O 10 2 1500 RPM 30 2 5000 RPM Spark Plug Gap Based on EU D
47. ers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Hold the plastic part of the lamp 1 Place the transmission in PARK Open the front rack cover 3 Remove the plug at the back of the ng headlight 4 Pull the harness plug to disconnect it from the back of the headlight 5 Position light Rotate the socket to remove it Go to step 6 Headlamp Reach under the bumper and remove the rubber cover from the back of the headlight Turn the collar counter clockwise and carefully remove the collar and socket Position Light _ Headlamp 6 Remove the lamp Apply dielectric grease to the socket and install a new lamp Socket 7 Reverse all steps to reassemble the 3 m headlight A bo E i 80 MAINTENANCE Lights Taillight Brakelight Lamp Replacement 1 From the rear of the brake a light remove the two 36 screws holding the lens a bd O cover in place Remove the lens cover e n 2 Remove the lamp and eee eth Lida a replace it with a new lamp Gage IEH T letro 3 Test the light for proper ko Lr x is rhe me EN operation 4 Reinstall the lens cover Ao Sirew Cover Turn Signal Lamp Replacement 1 Place the transmission in PARK 2 Remove the lens attachment screw 3 Rotate the lamp to remove it Install the new lamp 5 Reinstall the lens AIZA Ap Alb BKK 5 eal Ki F4 4 f g 1 Z f bese
48. friction to dry out the pads SAFETY Driving Safely Driving Through Water Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water CAUTION If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If your vehicle becomes fully immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 85 Have the vehicle serviced by your dealer promptly NOTE If water has been ingested into the transmission PVT follow the pro cedure on page 88 29 SAFETY Driving Safely Parking on an Incline Avoid parking on an incline If it s unavoidable follow these precau tions 1 Stop the engine 2 Place the transmission in PARK 3 Always block the rear wheels on the downhill side 4 Turn the fuel valve off 30 SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 Avoid backing down hill 2 Always check for obstacles or people behind the vehicle before backing 3 Drive slowly Apply the foot brake lightly for stopping 5 Avoid turning at sharp angles 6 Do not use the override switch unless additional power is required for vehicle movement Use with caution NOTE Reverse speed is greatly increased when the overri
49. g at low RPM low ground speed Utility use plowing Stuck in mud or snow Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Poor engine performance Slippage from failure to warm up belt Wrong or missing belt Improper break in 108 Solution Use low range if equipped Use low range if equipped or turn around using the K turn see page 26 Drive at a higher speed or use low range if equipped more frequently Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Use the throttle quickly and effectively Use low range only if equipped Use low range only if equipped Shift the transmission to low range if equipped Care fully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Dry out the PVT See page 88 Inspect clutch seals for damage if repeated leaking occurs See your Polaris dealer Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Always warm up the belt by operating below 48 km h for 1 6 km Operate 8 km or more when temperature is below freezing Install the recommended belt Always break in a new belt and or clutch See page
50. g systems Never operate on hills too steep for the Quadricycle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 25 Always follow the procedures outlined in this manual for climbing hills See page 22 A Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 25 Always follow the procedures outlined in this manual for crossing the side of a hill See page 24 Never attempt to turn the Quadricycle around on any hill until you ve mastered on level ground the turning technique outlined in this manual 10 SAFETY Operator Safety A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill See page 26 A Always follow the procedures outlined in this manual for operating over obstacles See page 21 A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 20 Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 28 11 SAFETY Operator Safety A Always follow the procedures outlined in this manual for driving in reverse See page 31 Always use the size and type of tires specified for your Qua
51. icle to overturn Split the load between the front rack and rear rack with 1 3 in the front and 2 3 in the back Do not exceed load capacities See specifications begin ning on page 112 SECURE ALL LOADS BEFORE OPERATING Unsecured loads can cre ate 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 fas ten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected caus ing the vehicle to overturn TOWING is approved OFF ROAD ONLY Operating a Quadricycle trailer combination on public roads is prohibited TOWING SPEED should never exceed 16 km h Never exceed 8 km h when towing loads in rough terrain while cornering or while ascending or descending hills 32 SAFETY Driving Safely Hauling Cargo Towing Loads Towing is approved OFF ROAD ONLY Operating a Quadricycle trailer combination on public roads is prohibited Do not exceed the maximum capacities when towing Do not tow any trailer on a grade steeper than 5 Maximum Towed Load Maximum Vertical Hitch Level Ground Weight 586 Kg Using an improper hitch or exceeding the Maximum maximum tongue weight capacity can 6 3
52. il 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 14 Install the new oil filter 62 After the filter contacts the engine surface turn it 1 2 turn by hand MAINTENANCE Oil and Filter Change 15 16 17 18 19 20 2i 22 23 Remove the dipstick Add the recommended oil See page 59 Reinstall the dipstick Start the engine Allow it to idle for two minutes Stop the engine Check for oil leaks Check the oil Safe Range level Add oil as lt needed Main tain the oil level in the safe range Do not Add Oil Safe overfill Reinstall the dipstick Discard used oil and filter properly 63 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Use the recommended oil Maintain the oil level at the bottom of the fill plug hole See page 107 for the part numbers of Polaris products The fill plug is located on the left side of the vehicle under the rear fender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission Premium AGL Synthetic 450 ml 20 N m 2x4 Gearcase Lubricant Transm
53. iliar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death A CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety A WARNING Failure to follow the warnings in this manual can result in serious injury or death A Polaris Quadricycle is not a toy and can be hazardous to operate A collision or rollover can occur quickly even during routine maneuvers if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris Quadricycle Safety Training When you purchased your new Quadricycle your dealer offered a hands on safety training course You were also provided with printed materials that explain safe operating procedures Review this informa tion on a regular basis If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer please request free safety training from any authorized Polaris dealer Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyon
54. ing 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 Charge Time Voltage Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfating charger 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 95 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish Do not use a
55. irective 76 432 EC 112 SPECIFICATIONS Hawkeye 2X4 International All wheel hydraulic disc All wheel hydraulic disc Hydraulic lock all wheel secondary Standard Reverse Indicator Standard Tripmeter Hourmeter Tool Kit DC Plug In rea Windshield Jetting Chart ALTITUDE Above 2700 Same main jet Remove 6 air box plugs Above 3000 Same main jet Remove 6 air box plugs Move jet needle clip to position 2 Clutching Chart Altitude Roller Number of Rollers Driven Clutch Meters Weight Spring 0 1500 13 g 5412988 PB 7043228 1500 3000 10 g 5412986 a 7043228 3000 10 g 5412986 6 7043228 Remove two opposite rollers to maintain clutch balance 113 SPECIFICATIONS Hawkeye 4X4 International Hitch Tongue Weight Capacity 34 kg Rear rack capacity and tongue weight not to exceed 45 kg Hitch Towing Rating 340 2 kg Capacity 92 Mikuni BST 34 Pilot Jet 42 5 1475 Ignition System 10 2 1500 RPM 30 2 5000 RPM Spark Plug Gap Based on EU Directive 76 432 EC 114 SPECIFICATIONS Hawkeye 4X4 International All wheel hydraulic disc All wheel hydraulic disc Hydraulic lock all wheel secondary Tripmeter Hourmeter Jetting Chart ALTITUDE AMBIENT TEMPERATURE C Meters Below 5 5 C and above 0 900 900 1800 Same main jet Remove 2 air box plugs 1800 2700 Same main jet Remove 4 air box plugs Above 2700 Same main jet Remove 6 air box plugs
56. ission Premium AGL Synthetic 600 ml 20 N m 4x4 Gearcase Lubricant 64 MAINTENANCE Transmission Oil Oil Check 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Use a 15 mm wrench 4 Check the oil level 5 Add the recommended oil as needed Do not overfill 6 Reinstall the fill plug Torque to specification See page 64 65 MAINTENANCE Transmission Oil Oil Change 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Use a 15 mm wrench 4 Place a drain pan under the gearcase 5 Remove the drain plug Use a 15 mm wrench 6 Allow the oil to drain completely 7 Clean and reinstall the drain plug Torque to specification See page 64 8 Add the recommended oil 9 Reinstall the fill plug Torque to specification See page 64 for recommenda tions 10 Check for leaks 11 Dispose of used oil properly 66 MAINTENANCE Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the inter vals outlined in the Periodic Maintenance Chart beginning on page 53 Use the recommended fluid Use of other fluids may result in improper operation of com ponents See page 107 for the part numbers of Polaris prod ucts Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the gearcase The
57. key fob or key ring to the main switch It may contact the gas tank cap when turning causing an interruption to the electrical sys tem and an unexpected engine shut down during operation This could result in serious injury or death Engine Stop Switch Engine The engine will not start or run when Stop Switch the switch is in the OFF position OFF wW RUN Light Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position An indicator light on the pod will illuminate when high beam is selected See page 36 High Beam A Low Beam 35 FEATURES AND CONTROLS Switches All Wheel Drive Switch 4x4 Models See page 44 for all wheel drive information AWD Switch Hazard Warning Switch A Push the hazard warning switch to cause all turn indicators to flash simultaneously Use this feature to alert others of an Turn Indicators emergency or other situation requiring caution High Beam Indicator Turn Signal Switch lt 10 gt Push the toggle switch either left or right to activate the corresponding turn signal The indicator on the console will also flash Return the toggle to the center position and push it inward to end the signal Horn Turn Signal Switch Switch Horn Switch bo Press the horn switch to sound the horn 36 FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed a
58. nd vehicle movement Release the lever to reduce engine speed and vehicle movement A WARNING Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Check the lever for proper operation before starting the engine Check occasionally during operation Do not start or operate a Quadricycle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Choke The choke assists in starting a cold engine See page 50 Mirrors Use the mirrors to assist in traffic maneuvers Always check and adjust the mirrors before driving the Quadricycle Electronic Throttle Control ETC ETC causes the engine to stop Electronic Throttle Control if the throttle cable sticks in an open position when the operator releases the throttle lever The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 37 FEATURES AND CONTROLS Foot Brake The all wheel foot brake is located on the right footrest The foot brake operates both front and rear brakes Press the brake pedal down with your foot to engage the all wheel brakes Foot Brake If the rear wheels begin to skid or slide while using the foot brake reduce brake pressure Hand Brake Lever The hand brake operates
59. nual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Please see your dealer for all of your service needs during and after the warranty period For more information about Polaris visit us online at www polarisin dustries com Ch POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2006 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2007 Hawkeye 2X4 Hawkeye 4X4 International Owner s Manual P N 9920788 2 TABLE OF CONTENTS Know Your Vehicle 0000000e 4 SAG ogg ete be care ad oe See ee a eee ets 5 Features and Controls 00005 34 Oprah asses sdeewek ete ene ai 47 Emission Control Syst
60. o raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 92 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage 94 MAINTENANCE 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 at 1 2 amps or less until battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging A WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charg
61. on the handlebars Apply the brakes Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the brakes Slowly squeeze the throttle lever toward the handlebar to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Driving Safely Turning the Vehicle 1 Before turning activate a turn signal to alert others of your intentions Activate the left signal before a left turn Acti vate the right signal before a right turn 2 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 Use the same leaning technique for turning in reverse 3 Practice turning at slow speeds before attempting to turn at faster speeds A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience A Always follow the procedures outlined in this manual for turning Never turn sharply at excessive speeds which can lead to vehicle overturn 19 SAFETY Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails gravel snow or ice follow these precautions 1 Slow down before driving onto slippery surfaces 2 Engage AWD before wheels begin to lose traction 4x4 models
62. r 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 PVT Drying If water is ingested into the PVT system dry it before operating the vehicle 1 Move the vehicle out of the water 2 Place the transmission in PARK 88 PVT System PVT Drying 3 Remove the PVT drain plug Use a 17 mm wrench a flat screw driver or the spark plug wrench 4 Allow the water to drain com pletely Reinstall the drain plug 5 Start the engine Place the trans mission in PARK 6 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 10 seconds 7 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible MAINTENANCE 89 MAINTENANCE Battery Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Conventional Battery Always keep battery terminals and connections fre
63. ransmission in PARK 3 Remove the arrestor clean out plug from the bottom of the muffler Start the engine 5 Quickly squeeze and release the throttle lever several times to purge car Clean Out Plug lt n bon from the system 6 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 7 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 5 8 If particles are still suspected to be in the muffler elevate the rear of the vehicle 30 cm higher than the front Block the wheels 9 Place the transmission in PARK Repeat steps 5 to 7 until no more particles are expelled 10 Stop the engine Allow the arrestor to cool 11 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 87 MAINTENANCE PVT System A WARNING 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 you
64. rd counterclockwise to lower RPM Adjuster 105 ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 Locate the throttle cable adjuster at the handlebar 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Boot _ gt 3 Loosen the adjuster lock nut Lock Nut Adjuster 4 Rotate the boot to turn the adjuster until 1 6 3 2 mm of freeplay is achieved at the thumb lever NOTE Move the throttle lever S back and forth while adjusting gt lt 1 6 3 2 mm 5 Tighten the lock nut 6 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position NOTE Engine RPM should not increase when steering is turned full left or right Readjust cable freeplay if this occurs 106 POLARIS PRODUCTS Part Number Description 2870797 2874865 2874866 Performance Synthetic 4 Stroke PS 4 OW 50 Oil 3 8 1 2873602 2873603 2870465 2871654 2872277 2871312 2871322 2871423 2871460 287158 2871557 2872073 2872348 2872889 2871326 2870652 2872188 2872893 2871076 107 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed 3 7 MPH Insufficient warm up at low ambient tempera tures Slow easy clutch engage ment Towing pushin
65. s or using a non recommended oil may cause serious engine damage Always use a recommended oil Never substitute or mix oil brands Oil Specifications Capacity Drain Plug Torque Performance Synthetic 1 9 liters 19 N m 4 Stroke PS 4 OW 50 59 MAINTENANCE Engine Oil Oil Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine Allow it to idle for 30 seconds 4 Stop the engine 5 Remove the dipstick Eas Wipe it dry with a clean Dipstick cloth 6 Reinstall the dipstick completely E 7 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Safe Range n 8 Reinstall the dipstick 60 MAINTENANCE Oil and Filter Change 4 CAUTION Hot oil may result in serious burns Do not allow hot oil to contact skin 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine Allow it to idle for two minutes 4 Stop the engine 5 Clean the area around the drain plug 6 Place a drain pan under the vehicle 7 Remove the drain plug Use a 6 mm Allen wrench 8 Drain the oil 9 Clean the drain plug Reinstall the drain plug with a new sealing washer gt gt 10 Torque to specification See page 59 61 MAINTENANCE Oil and Filter Change 11 12 13 Place towels under the oil filter Using an o
66. se or see your dealer 53 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions E Have an authorized Polaris dealer perform these services A WARNING Improperly performing the procedures marked with a W could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 54 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first pene eres Miles Km i rene Pre Ride Ride Make adjustments as need at See Pre Ride Checklist Front suspension Front suspension Pre Ride on page 49 rare ree ps Pere Beke Muidtever Prene Brakele Pre Ride Foree Prena Brake system Pre Ride ae Wheelsfasteners Prene Fame tasien Prene Engine oil level Pre Ride 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 Air filter Weekly Inspect replace as needed main element Recoil housing Weekly Drain water as needed if applic
67. service 10 Reinstall the sleeve over the air filter Replace the filter if needed 11 Reinstall the air filter into the air box Tighten the clamp Do not over tighten the clamp as filter damage could occur 12 Reinstall the air box cover and the seat 78 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 1 Position the vehicle on a level surface with the headlight approxi mately 7 6 m from a wall 2 Place the transmission in PARK 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 4 Start the engine Turn the headlight switch to high beam 5 Observe the headlight aim on the wall The most intense part of the headlight beam should be 5 cm below the mark on the wall 6 Tighten or loosen the lower headlight screws to adjust the beam upward or downward or to the left or right 79 MAINTENANCE Lights A WARNING Poor lighting can result in loss of control or an accident Lights become dirty during normal operation Wash the headlights and taillights frequently Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled Headlight Position Light Lamp Replacement When servicing a halogen lamp do not touch the lamp with bare fing
68. sts that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 118 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed MILES KM OR HOURS MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 120 A ACCESSO ES 4c Bite lel a hehe 101 Age Restrictions 6 Ae PU ei zaorit 4 Bai sed eeu ave sb shack 78 All Wheel Drive Switch 36 All Wheel Drive System 44 AWD Syse 0c ou A oe tee ea 44 B Battery Charging Conventional 94 Charging Sealed 94 95 Conventional 90 Fluid Conventional 93 Installation 92 Removals 42 355 205 oe 91 SOLAS hamn o redux Seis Seles 93 DOOWS 4 4s og bacon eae oak es 17 Brake Fluid 70 72 Brake Inspections 73 Brake Foot
69. t 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 52 MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions and average vehicle speed of approximately 16 km h Vehicles subjected to severe use must be inspected and serviced more frequently Record maintenance and service in the Maintenance Log beginning on page 119 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 Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cau
70. tches AWD Switch 2 0 2508228 eeu 36 Engine Stop Switch 35 Hazard Warning 36 TOU 2 iets OG ENOR eel 36 Light SWIC oiee hears Se eo es 35 Main Key Switch 35 Mode Reverse Override Switch 34 T rn Srenah ocd po tne eos oes 36 T TAM NG sis E E ee ah a 81 Throttle Cable Freeplay 106 Throttle Lever r iso asics hae ees ened 37 Tire Tread Depth 76 Tires Front Wheel Hub Tightening 76 Tread Depth 76 Wheel Installation LY Wheel Nut Torque 76 Wheel Removal ce Toe Alignment 74 Towing a Disabled Vehicle 102 Towing Loads 2 i242 Ace ees 33 Training Safety esr oe eee ares 6 Transmission Oil 64 66 Transporting the Vehicle 102 Turn Signal Lamp 81 Turn Signal Switch 36 Turning Around ona Hill 26 27 Turning the Vehicle 19 INDEX V Vehicle Identification Numbers 4 Vehicle Immersion 85 86 W Warning Symbols 5 Washing the Vehicle 96 97 Wheel Hub Tightening 76 Wheel Installation TI Wheel Nut Torque Specifications 76 Wheel Removal 77 123
71. the information found on each decal General Alert Multi Lingual Before you operate this vehicle read the owner s manual A Hill Operation Alert e Never operate this vehicle on HILLS p steeper than 25 degrees 25 AET e To ee ees hilly terrain LANG ess when going up or down use throttle mole a and brakes gradually Alert 14 SAFETY Safety Decals and Locations Rack Rack Warning Warning No Passenger Warning Tire Pressure Load Alert A No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH A Tire Pressure Load Alert TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 930 LBS 423 kg Read Owner s Manual for more detailed loading information A Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rack Loads Front 70 Ibs 32 kg Rear 100 Ibs 46 kg A Reverse Override Alert 4X4 Models 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 15 SAFETY Safe Riding Gear Always wear protective
72. tional batteries ase I remove the battery vent SJ tube gt cs See i 4 AYDA 5 Disconnect the black nega 5 R AY tive battery cable first Ke 6 Disconnect the red posi Ja tive battery cable last 7 Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 9 MAINTENANCE Battery Battery Installation 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte A WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 On conventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Secure the battery hold down strap NH wv Verify that cables are properly routed
73. ttempt to turn the Quadricycle around on any hill until you ve mastered on level ground the turning technique outlined in this manual arn ie 24 SAFETY Driving Safely Driving Downhill When driving downhill follow these precautions 1 Check the terrain carefully 2 Avoid hills with excessively slippery or loose surfaces 3 Never drive downhill at high speed Slow down 5 Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side Drive straight downhill 6 Shift your weight rearward 7 Apply the brakes slightly to aid in slowing A Always follow the procedures outlined in this manual for driving downhill and for braking on hills Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience 29 SAFETY Driving Safely Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 1 Stop the vehicle Keep your weight uphill 2 Lock the hydraulic parking brake 3 Leave the transmission in forward gear Turn the engine off 4 Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill 5 Stay uphill of the vehicle and turn the handlebars full left 6 Squeeze the brake lever to release the parking brake 7 Slowly release the brake lev
74. wheels from corrosion pre serve wheel life and ensure a like new appearance for many years NOTE Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 98 MAINTENANCE Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 96 Stabilize the Fuel 1 Fill the fuel tank
75. ys switch to AWD while the rear wheels have traction or are at rest AWD When the AWD switch is on the Quadricycle is in four wheel drive and the differential is locked providing maximum traction The demand drive unit automatically engages when the rear wheels lose trac tion When the rear wheels regain traction the demand drive unit automatically disengages 2X4 When the 2X4 switch is on the Quadricycle is in two wheel drive at all times and the differential is locked 44 FEATURES AND CONTROLS Instrument Cluster The instrument cluster mea sures distance in kilometers or miles as well as hours of oper ation It also includes a reverse speed limiter function that lim its vehicle speed to approxi mately 11 14 km h Refer to page 34 for additional informa tion CAUTION To prevent damage wash the vehicle 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 contact the lens Miles Kilometers Toggle The display in the tripmeter odometer and speedometer can be changed to display either kilometers or miles 1 To change modes press and release the mode button see page 31 as often as needed to reach the odometer mode 2 Inthe odometer mode press and hold the mode button until the let ters flash then release the button 3 Press

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