Polaris Hawkeye 922362 Owner's Manual
Polaris Hawkeye 922362 Owner's Manual

Polaris Hawkeye 922362 Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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Pantone 426 C
HAWKEYE 2X4
Owner's Manual
for Maintenance and Safety
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.

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Summary of Contents for Polaris Hawkeye 922362

  • Page 1 Pantone 426 C HAWKEYE 2X4 Owner's Manual for Maintenance and Safety 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.
  • Page 2 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 3 FOLLOW ALL INSTRUCTIONS AND WARNINGS. Pantone 426 C NEVER CARRY NEVER USE PASSENGERS WITH DRUGS OR ALCOHOL For your nearest Polaris dealer, visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A. Part No. 9922362 Rev 02 Printed in U.S.A.
  • Page 4 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles ®...
  • Page 5 POLARIS, THE WAY OUT and HAWKEYE are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.
  • Page 6: Table Of Contents

    Maintenance ......54 Polaris Products..... . . 105 Troubleshooting .
  • Page 8: Introduction

    The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
  • Page 9: Safety Training

    Failure to follow the warnings in this manual can result in serious injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.
  • Page 10: 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.
  • Page 11: Safety

    Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com. Never permit others to operate this vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.
  • Page 12 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 this vehicle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.
  • Page 13: Operator Safety

    SAFETY Operator Safety Always inspect your vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 35. Keep both hands on the handlebars. Keep both feet on the footrests. Always travel slowly when operating on unfamiliar terrain.
  • Page 14 See page 39. If this vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.
  • Page 15 SAFETY Operator Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 44. Always follow the procedures outlined in this manual for operating over obstacles.
  • Page 16 Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. For more information about safety, contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com.
  • Page 17: General Warning

    Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge.
  • Page 18: Discretionary Warning

    Safety Labels and Locations Discretionary Warning WARNING • Never operate this ATV on HILLS steeper than 25 degrees To prevent overturn on hilly ter- rain, use throttle and brakes grad- ually, and shift weight uphill. • REVERSE operation can be dan- gerous even at low speeds.
  • Page 19: No Passenger" Warning

    SAFETY Safety Labels and Locations Age 16 Warning Rack Warning “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
  • Page 20: Clutch Cover Warning

    Safety Labels and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.
  • Page 21: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Eye Protection Long Helmet Sleeves Gloves Long Pants Boots 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.
  • Page 22: Eye Protection

    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.
  • Page 23: Features And Controls

    FEATURES AND CONTROLS Switches Headlight Main Key Switch Switch Engine Mode/Reverse All Wheel Drive Switch Stop Switch Override (4X4 Models) Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch. The override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on.
  • Page 24: Engine Stop Switch

    FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights.
  • Page 25 Contact your dealer for repair if throttle problems arise. Electronic Throttle Control (ETC) This vehicle is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.
  • Page 26: Brake Lever

    FEATURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding.
  • Page 27: Parking Brake

    Parking Brake Operating this vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1. Place the transmission in gear.
  • Page 28 FEATURES AND CONTROLS Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.
  • Page 29: Fuel Valve

    FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 36 for correct choke and throttle settings during start- ing. Fuel Tank Cap Fuel Tank Remove the fuel tank cap to add fuel to the fuel tank.
  • Page 30 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear Gear selector is located on the Selector right side of the vehicle. H: High Gear N: Neutral R: Reverse Whenever this vehicle is left unattended, always place the transmission in gear and lock the parking brake.
  • Page 31: Recoil Starter

    FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 36, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly.
  • Page 32: Engaging Awd

    FEATURES AND CONTROLS All Wheel Drive (AWD) System (4X4 Models) The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the vehicle is in two-wheel drive at all times. When the switch is on AWD, the vehicle is in all wheel drive and the AWD indicator light Switch...
  • Page 33 FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits this vehicle's speed to approximately 7-9 mph.
  • Page 34: Instrument Cluster

    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.
  • Page 35: Operation

    OPERATION Fuel Safety 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 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.
  • Page 36: Break-In Period

    Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the proce- dures for a proper break-in.
  • Page 37 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. 2. Check the oil level on the dipstick. See page 61. Add oil if neces- sary to maintain the level between the safe and add marks. 3.
  • Page 38: Pre-Ride Checklist

    Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles, and...
  • Page 39: Starting The Engine

    OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3.
  • Page 40: Cold Weather Operation

    Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accu- mulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. OPERATION...
  • Page 41 OPERATION Driving Procedures 1. Wear protective riding gear. See page 18. 2. Perform the pre-ride inspection. See page 35. 3. Sit upright with both feet on the footrests and both hands on the handlebars. 4. Start the engine and allow it to warm up. 5.
  • Page 42: Turning The Vehicle

    Turning the Vehicle Your vehicle is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.
  • Page 43: Driving On Slippery Surfaces

    Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather, follow these precautions: 1. Do not operate on exces- sively rough, slippery or loose terrain. 2. Slow down when enter- ing slippery areas.
  • Page 44: Driving Uphill

    OPERATION Driving Uphill 25° Maximum Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2.
  • Page 45 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.
  • Page 46: Driving Downhill

    OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Before operating your vehicle, learn how to use the auxiliary brake for emergency situations (if single-lever brakes become inoperable). 2. Always check the terrain carefully before descending a hill. 3. Shift your weight uphill. 4.
  • Page 47 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m)
  • Page 48 Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the vehicle, or on the left if the vehi- cle is pointing straight uphill.
  • Page 49: Driving Through Water

    OPERATION Driving Through Water Maximum Depth Your vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3.
  • Page 50 OPERATION Driving Through Water If it’s unavoidable to enter water deeper than the footrest level: • Proceed slowly. Avoid rocks and obstacles. • Balance your weight carefully. Avoid sudden movements. • Maintain a steady rate of speed. Do not make sudden turns or stops. Do not make sudden throttle changes.
  • Page 51: Driving Over Obstacles

    OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3.
  • Page 52: Driving In Reverse

    Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles.
  • Page 53: Hauling Cargo

    OPERATION Hauling Cargo 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.
  • Page 54: Towing Loads

    Never install a hitch longer than 6 3/4" (17 cm). Never install automotive accessories on your Polaris vehicle. Always install Polaris-approved (or equivalent) accessories designed for use on your vehicle.
  • Page 55: Parking On An Incline

    OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5.
  • Page 56: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.
  • Page 57: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 118.
  • Page 58: Periodic Maintenance Chart

    Improperly performing the procedures marked with a could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use.
  • Page 59 (if equipped) Transmission oil Engine breather filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride Pre-Ride...
  • Page 60 Periodic Maintenance Chart Item Hours Calendar General lubrication Carburetor float bowl Throttle Cable/ ETC Switch Choke cable E Carburetor air intake ducts/flange Drive belt Engine oil change Oil filter change Oil tank vent hose (if equipped) Valve clearance Fuel system/filter Engine mounts Exhaust muffler/ pipe...
  • Page 61 Spark arrestor Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 100 H 12 M 1000 (1600) Inspect;...
  • Page 62: Lubrication Guide

    Control Arm (front and rear) Bearing Carrier Transmission (upper pivot point) Front Prop Shaft Yoke Lube PS-4 PLUS Performance Synthetic 2W-50 DOT 4 Only Polaris AGL Synthetic Gearcase Lube Premium Demand Drive Hub Fluid Polaris Premium U-Joint Lube Bearing Carrier MAINTENANCE Method See page 60.
  • Page 63: Engine Oil

    Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient tempera- ture operation.
  • Page 64: Oil Level

    Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the vehicle. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Start the engine. Allow it to idle for 30 seconds.
  • Page 65: Oil And Filter Change

    Oil and Filter Change Hot oil may result in serious burns. Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Always change the oil filter whenever changing oil.
  • Page 66 Oil and Filter Change 11. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove 12. Clean the filter sealing area on the engine. 13. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition.
  • Page 67: Transmission Oil

    54. Maintain the oil level at the bottom of the fill plug hole. See page 105 for the part numbers of Polaris products. The fill plug is located on the left side of the vehicle, under the rear fender, behind the wheel. The drain plug is located behind the wheel well.
  • Page 68: Oil Check

    Transmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Check the oil level. 6. Add oil as needed. Do not overfill.
  • Page 69: Oil Change

    MAINTENANCE Transmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Place a drain pan under the gearcase.
  • Page 70 Periodic Maintenance Chart beginning on page 54. We recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of compo- nents. See page 105 for the part numbers of Polaris products.
  • Page 71 MAINTENANCE Front Gearcase (Demand Drive) Fluid (if equipped) Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5.
  • Page 72: Fluid Change

    Front Gearcase (Demand Drive) Fluid (if equipped) Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Place a drain pan under the gearcase.
  • Page 73: Brake Fluid

    Never operate the vehicle with spongy-feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 105 for the part numbers of Polaris products. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
  • Page 74 Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Main- tain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder. Do not over- fill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight.
  • Page 75: Brake Inspections

    Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommended to keep the brake system in good operating condition.
  • Page 76: Toe Alignment

    2-3 mm more than the front measurement on each side of the vehicle to obtain the recommended 3-6 mm toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your Polaris dealer for ser- vice. MAINTENANCE...
  • Page 77: Spring 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. Tip: Accessory springs are available through your Polaris dealer. Rear Adjuster Front...
  • Page 78 Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Loosen the four handlebar bolts.
  • Page 79 Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient opera- tion. Optional jets, available from your Polaris dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.)
  • Page 80: Throttle Cable Freeplay

    Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3.
  • Page 81: Side Panel Removal

    MAINTENANCE Steering Assembly The steering assembly of this vehicle should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat.
  • Page 82: Tire Tread Depth

    1/8" (3 mm) when tread depth is worn to 1/8" (3 mm) or less. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer.
  • Page 83: Wheel Removal

    Tires Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Loosen the wheel nuts slightly. 5. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground.
  • Page 84: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the wheel on the wheel hub with the valve stem...
  • Page 85 Air Filter/Breather Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the seat. 5. Release the air box cover clips, and remove the air box cover. 6. Remove the air filter. 7.
  • Page 86: Headlight Beam Adjustment

    Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2.
  • Page 87: Headlamp Replacement

    Lights 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. Headlamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers.
  • Page 88: Recoil Housing

    Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the housing before storing the vehicle. Make sure the hous- ing is completely dry before reinstalling the drain plug. 1. Place the transmission in gear. 2.
  • Page 89: Spark Plugs

    Spark Plug Recommendations Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 110 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification.
  • Page 90: Spark Plug Condition

    Spark Plugs Spark Plug Inspection 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation. 5. Reverse the procedure for spark plug installation. Torque to specification. Spark Plug Condition Normal Spark Plug The normal insulator tip is gray, tan or light brown.
  • Page 91: Vehicle Immersion

    MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.
  • Page 92: Spark Arrestor

    Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.
  • Page 93: Pvt System

    • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 94: Pvt Drying

    PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Move the vehicle out of the water. 2. Remove the PVT drain plug. Use a 17 mm wrench, a flat screwdriver, or the spark plug wrench.
  • Page 95 MAINTENANCE Battery 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. WARNING Battery electrolyte is poisonous.
  • Page 96: Battery Removal

    Battery Battery Removal 1. Place the transmission in gear. 2. Lock the parking brake. 3. Open the front cover. 4. Disconnect the battery hold- down strap. 5. On conventional batteries, remove the battery vent tube. 6. Disconnect the black (nega- tive) battery cable first.
  • Page 97: Battery Installation

    MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 96 before installing the battery.
  • Page 98: Battery Storage

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge.
  • Page 99 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 93. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 100 Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less MAINTENANCE Action charger @ standard amps specified on top of battery)
  • Page 101: Cleaning And Storage

    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.
  • Page 102: Polishing The Vehicle

    Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 103 Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
  • Page 104: Storage Tips

    98. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 105 7. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 106 2. 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.
  • Page 107: Transporting The Vehicle

    Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Turn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6.
  • Page 108: Polaris Products

    2872348 Chain Lube, Aerosol (16 oz.) 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Brake Fluid (12 oz.) 2871956 Loctite 2859044 Polaris Battery Tender POLARIS PRODUCTS Engine Lubricant Additives / Miscellaneous 565 Thread Sealant Charger...
  • Page 109: Troubleshooting

    Dry out the PVT. See page 91. 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.
  • Page 110 Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Inspect, clean and/or replace spark plugs Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark...
  • Page 111 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Idle set too low Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections...
  • Page 112: Engine Overheating

    Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Overuse of choke Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel...
  • Page 113: Specifications

    78.5 x 68 250 w 9.2:1 Mikuni BST 34 0-5M 4HC57-3 DC CDI 10° +/- 2° @ 1500 RPM/30° +/- 2° @ 5000 RPM NGK CR8EB / .031 in. (0.8 mm) Automatic PVT (Polaris Variable Transmission) Side Lever (H/N/R) 15.18:1...
  • Page 114: Jetting Chart

    Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery DC Plug-In (rear) Windshield Speedometer/Odometer/ Tripmeter/Hourmeter Fuel Gauge Tool Kit Jetting Chart ALTITUDE Meters (Feet) 0-900 (0-3000) 900-1800 (3000-6000) 1800-2700 (6000-9000) Above 2700 (Above 9000)
  • Page 115 299 cc 78.5 x 68 250 w 9.2:1 Mikuni BST 34 0-5M 4HC57-3 DC CDI 10° +/- 2° @ 1500 RPM/30° +/- 2° @ 5000 RPM NGK CR8E / .031 in. (0.8 mm) Automatic PVT (Polaris Variable Transmission) Side Lever (H/N/R)
  • Page 116 Drive Ratio, Front Drive Ratio, Final Tires/Pressure, Standard models Tires/Pressure, LE models Front Suspension Rear Suspension Shock Adjustment Brakes, Front and Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery DC Plug-In (rear) Windshield Speedometer/Odometer/ Tripmeter/Hourmeter Fuel Gauge Tool Kit Jetting Chart ALTITUDE Meters (Feet)
  • Page 117: Declaration Of Conformity

    Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES 98/37/EC as amended (Machinery Directive)
  • Page 118: 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 vehicle that...
  • Page 119 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination, for which they were not designed or not intended, including but not limited to the following items: • Wheels and tires •...
  • Page 120 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.
  • Page 121: Maintenance Log

    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- med. vices perfor DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 122 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 123 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 124: Index

    Accessories ....103 Age Restrictions ....6 Air Filter .
  • Page 125 Periodic Maintenance Chart ..54-58 Polaris Product List ... . . 105 Polishing the Vehicle... . . 99 Pre-Ride Checklist.
  • Page 126: Index

    Switches AWD Switch... . 21, 29 Engine Stop Switch..21 Headlight Switch... . 21 Main Key Switch .

This manual is also suitable for:

Hawkeye 2x4 2010

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