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Polaris Hawkeye 9921770 Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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Summary of Contents for Polaris Hawkeye 9921770

  • Page 3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • Quadricycles • RANGER utility vehicles •...
  • Page 4 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 5: Table Of Contents

    Adjustments ......101 Polaris Products..... . . 105 Troubleshooting .

  • Page 7: Know Your Vehicle

    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 8: Safety

    Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

  • Page 9: Safety Training

    You were also provided with printed materials that explain safe operating procedures. Review this informa- tion on a regular basis. If you purchased your vehicle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer. Age Restrictions This vehicle is an ADULT VEHICLE ONLY.

  • Page 10: Operator 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 under- stand this manual and all product labels, and have completed a certified safety training course.
  • Page 11 SAFETY Operator Safety Always wear an approved helmet that fits properly. Wear eye protec- tion (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the ter- rain, visibility, operating conditions and your experience.
  • Page 12 SAFETY Operator Safety Always inspect your vehicle before each use to verify that it's in safe oper- ating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 35. Keep both hands on the handlebars. Keep both feet on the footrests. Always travel slowly when operating on unfamiliar terrain.
  • Page 13 See page 41. If this vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering sys- tems.
  • Page 14 SAFETY Operator Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 46. Always follow the procedures outlined in this manual for operating over obsta- cles.
  • Page 15 Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. For more information about safety, contact an autho- rized Polaris dealer or visit the Polaris web site at www.polarisindustries.com.

  • Page 16: General Warning

    If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

  • Page 17: Discretionary Warning

    Safety Decals and Locations Discretionary Warning WARNING • Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually. • REVERSE operation can be dangerous even at low speeds.

  • Page 18: No Passenger" Warning

    SAFETY Safety Decals 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 19: Clutch Cover Warning

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

  • Page 20: 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 21: 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 22: Features And Controls

    Switches Headlight Switch Mode/Reverse Override Switch Activating the override switch while the throttle is open can cause loss of con- trol, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch.

  • Page 23: Engine Stop Switch

    Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. NOTE: Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights.

  • Page 24: Throttle Lever

    Engine speed returns to idle when the lever is released. This vehicle is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

  • Page 25: Brake Lever

    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 26: 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 27 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 28: 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 29 Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear N: Neutral R: Reverse Whenever this vehicle is left unattended, always place the transmission in gear and lock the parking brake.

  • Page 30: 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 31: Engaging Awd

    All Wheel Drive (AWD) System (4X4 Models) The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the vehicle is in two-wheel drive at all times. When the switch is on AWD, the vehicle is in all wheel drive and the AWD indicator light in the instrument cluster will be When in AWD, the demand drive unit will automatically engage any...

  • Page 32: Instrument Cluster

    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 33: Rider Information Center

    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 34: Operation

    OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 35 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 36 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 37: 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 38: 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 39: 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. CAUTION...

  • Page 40: Hauling Cargo

    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. CAUTION 6 3/4"...
  • Page 41 OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 42: Driving Safely

    Driving Safely Driving Procedures 1. Wear protective riding gear. See page 18. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.

  • Page 43: Turning The Vehicle

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

  • Page 44: Driving On Slippery Surfaces

    Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather, follow these precautions: 1. Slow down when enter- ing slippery areas. 2. Engage AWD before wheels begin to lose traction.

  • Page 45: Driving Uphill

    Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25° maximum). 3. Keep both feet on the footrests. 4. Shift your weight uphill. 5. Proceed at a steady rate of speed and throttle opening. 6.
  • Page 46 Driving Safely Driving on a Sidehill (Sidehilling) Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.

  • Page 47: Driving Downhill

    Driving Safely Driving Downhill Excessive speed when traveling downhill can cause loss of control and seri- ous injury or death. Slow down. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control and serious injury or death. Apply the brakes gradually.
  • Page 48 OPERATION Driving Safely Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m)
  • Page 49 Driving Safely Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the vehicle, or on the left if the vehi- cle is pointing straight uphill.

  • Page 50: Driving Through Water

    OPERATION Driving Safely 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.
  • Page 51 Driving Safely Driving Through Water After running the vehicle in water, it's critical to have it serviced as out- lined in the maintenance chart. See page 54. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

  • Page 52: Driving Over Obstacles

    OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hid- den obstacle.

  • Page 53: Driving In Reverse

    Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Your Polaris vehicle is equipped with a reverse speed limiter. Use the override button with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle.
  • Page 54 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5.

  • Page 55: Emission Control Systems

    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.

  • Page 56: 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 117.

  • Page 57: Periodic Maintenance Chart

    Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a ponent failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. MAINTENANCE...
  • Page 58 (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 59 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 60 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 61: 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 62: 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 63: 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 64: Oil And Filter Change

    Oil and Filter Change Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Always change the oil filter whenever changing oil.
  • Page 65 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 66: 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 67 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 68: 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 69 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 70 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Check the oil level. 6.

  • Page 71: Fluid Change

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

  • Page 72: Brake Fluid

    Do not overfill. If the fluid level is low add DOT 4 brake fluid only. See page 105 for the part numbers of Polaris products. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
  • Page 73 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 74: 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 75: Toe Alignment

    3-6 mm toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. NOTE: If you discover improper alignment, see your Polaris dealer for service. MAINTENANCE WARNING Stand...

  • Page 76: 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 77: Tire Tread Depth

    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. MAINTENANCE WARNING 1/8" (3 mm)

  • Page 78: Wheel Removal

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

  • Page 79: 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...
  • Page 80 MAINTENANCE Air Filter/Breather Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the seat. 5. Release the air box cover clips, and remove the air box cover. 6.

  • Page 81: 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 82: Headlamp Replacement

    Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 83: 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 84: 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 85: 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 86: Vehicle Immersion

    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 87: 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 88: 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 89: 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 screw- driver, or the spark plug wrench.

  • Page 90: Conventional Battery

    MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Battery Always keep battery terminals and connections free of corrosion.

  • Page 91: Battery Removal

    Battery Improperly connecting or disconnecting battery cables can result in an explo- sion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.

  • Page 92: 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 92 before installing the battery.

  • Page 93: Battery Storage

    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.
  • Page 94 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 89. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 95 Battery Battery Charging (Sealed Battery) NOTE: 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...

  • Page 96: Cleaning And Storage

    Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

  • Page 97: Polishing The Vehicle

    • Cab and body panels • Labels and decals NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
  • Page 98 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 99: Storage Tips

    Make any necessary repairs and clean the vehicle as recommended. See page 94. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE:...
  • Page 100 7. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 101 Accessories Auxiliary power outlets provide 12-volt power for operating accesso- ries. Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your vehicle. Always install accessories that are approved for use with this vehicle. Please see your Polaris dealer.

  • Page 102: 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 103: Adjustments

    The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Always adjust both sides equally. NOTE: Accessory springs are available through your Polaris dealer. Rear Adjuster Front Adjuster...
  • Page 104 Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Loosen the four handlebar bolts.
  • Page 105 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 106: 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 107: 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 108: Troubleshooting

    Dry out the PVT. See page 87. 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 109 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 110 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 111: 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 112: 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 113: 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 114 299 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 115 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 116: Warranty

    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.
  • Page 117 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...
  • Page 118 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris Quadricycles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

  • Page 119: 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- vices performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 120 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 121 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 122: Index

    Accessories ....99 Age Restrictions....7 Air Filter .
  • Page 123 Periodic Maintenance Chart ..54-58 Polaris Product List... . . 105 Polishing the Vehicle ... . 95 Pre-Ride Checklist .
  • Page 124 Switches AWD Switch ... 21, 29 Engine Stop Switch ..21 Headlight Switch ... 21 Main Key Switch .

This manual is also suitable for:

Hawkeye 20082x4 2008

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