Polaris Hawkeye 9922016 User Manual

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Quadricycles

• RANGER utility vehicles

• Victory motorcycles Always follow the instructions and recommendations in this manual.

The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician. 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.polarisindustries.com.

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2008 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 discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2009 Hawkeye 2X4 Owner’s Manual P/N 9922016

TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Emission Control Systems . . . . . . . . . . . . . . . 53

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 105

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 106

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 110

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 117

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

KNOW YOUR VEHICLE

####

VIN

Engine Serial Number

Key Number

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 information about all aspects of your vehicle, including safe operating procedures.

Ride responsibly. Know all laws and regulations concerning the operation 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.

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 symbols 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.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

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

WARNING

Failure to follow the warnings in this manual can result in serious injury or death. This 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.

Read and understand your owner's manual and all warnings before operating this vehicle.

Safety Training

When you purchased your new Polaris vehicle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information 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. Operation is prohibited for anyone under 16 years of age.

Equipment Modifications

The warranty on your Polaris vehicle 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 handling. Use only Polaris-approved accessories. Know their function and effect on the vehicle.

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual.

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating this vehicle.

Never operate this vehicle without proper instruction. 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.

Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.

Never allow anyone under 16 years of age to operate this vehicle.

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.

SAFETY

Never attempt jumps or other stunts.

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. Use extra caution.

Use caution when operating on rough, slippery or loose terrain.

Operator Safety

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn. 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 systems.

Always follow the procedures outlined in this manual for driving on hills. See page 43. Never operate on hills too steep for this vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 15°.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 45.

SAFETY

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 44. Never attempt to turn this vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

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 obstacles. See page 50.

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

42.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 48.

Always follow the procedures outlined in this manual for driving in reverse. See page 51.

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

SAFETY

Operator Safety

Never modify this vehicle through improper installation or use of accessories.

Never exceed the stated load capacity for your vehicle. 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.

Never operate this vehicle on a frozen body of water.

Always avoid operating this vehicle on paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate this vehicle on a public street, road or highway, including a dirt or gravel road.

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

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.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions of the decals on the vehicle carefully. If any of the decals depicted in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle.

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

General Warning

WARNING Improper ATV use can result in

SEVERE INJURY or DEATH ALWAYS USE AN APPROVED

HELMET AND PROTECTIVE GEAR

NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR

ALCOHOL NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

• on public roads - a collision can occur with another vehicle

• with a passenger - passengers affect balance and steering and increase risk of losing control

ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175376

Safety Decals and Locations

Discretionary Warning

WARNING

• Never operate this ATV on HILLS

steeper than 25 degrees 25°. To prevent overturn on hilly terrain, use throttle and brakes grad-

ually, and shift weight uphill.

• REVERSE operation can be dan-

gerous even at low speeds. Steering becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.

7175511

Tire Pressure/Load Warning

WARNING Improper tire pressure or overloading can

cause loss of control. Loss of control can result in severe injury

or death.

• Cold tire pressure:

Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa)

• Maximum weight capacity: 385 lbs.

(175 kg)

7175442

SAFETY

“No Passenger”

Warning

Clutch Cover

Warning

Age 16 Warning

Rack

Warning

Rack

Warning

Safety Decals and Locations

“No Passenger” Warning

WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or

DEATH.

7175378

Age 16 Warning

WARNING Operating this ATV if you are under the age of 16 increases your chance of

severe injury or death. NEVER operate this ATV if you are under age 16.

7175374

SAFETY

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.

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.

• Max Rack Loads: Front 70 lbs. (32 kg) Rear 100 lbs. (46 kg)

Reverse Override Warning (4X4 Models)

WARNING Improper use of override button can lead to loss of control resulting in severe

injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse.

Override Switch (2X4 Models)

Reverse speed is limited. Reverse override is controlled by the override switch. See your Owner's Manual.

All Wheel Drive Switch (4X4 Models)

Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner's Manual.

Hitch Capacity Label

TRAILER MAX WEIGHT: 750 LBS. (340 KG) ON LEVEL GROUND HITCH MAX. VERTICAL WEIGHT: 75 LBS. (34 KG)

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet

Always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever 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.

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Main Key Switch

Engine

Stop Switch

Headlight

Switch

All Wheel Drive Switch

(4X4 Models)

Switches

WARNING

Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open.

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch.

NOTE: The override switch also allows activation of All Wheel Drive in

reverse, if the AWD switch is on. This switch is also used to toggle through the modes of the rider information center. See page 30.

FEATURES AND CONTROLS

OFF OFFRUN

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-

Main Key Switch

Use the main key switch to start the engine. See page 36 for starting procedures.

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam.

NOTE: The lights won't work unless the key is in the ON position and the

Operating this vehicle on streets or roads, especially in darkness, could result in an accident and serious injury or death.

Your vehicle is not equipped with highway-approved lights. It's designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

cal power to the vehicle, including lights.

engine stop switch is in the RUN position.

WARNING

All Wheel Drive Switch (4x4 Models)

See page 29 for all wheel drive information.

FEATURES AND CONTROLS

Throttle Lever

WARNING

Operating this vehicle with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death.

Never start or operate this vehicle with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation.

Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever is spring loaded. 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.

WARNING

Modifications to the ETC could result in failure to perform as designed, which could result in severe injury or death. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms. Always ensure that the throttle cable is properly installed to the ETC.

FEATURES AND CONTROLS

Brake Lever

Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.

Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

WARNING

Operating this vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate this vehicle with a spongyfeeling brake lever.

FEATURES AND CONTROLS

Parking Brake

WARNING

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.

2. Squeeze and release the brake

lever two or three times, then squeeze and hold.

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. It will return to its unlocked position.

Important Safeguards

• The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling.

• Always block the wheels on the downhill side of this vehicle if leaving it parked on a hill. Another option is to park in a sidehill position.

• Never depend on the parking brake alone if this vehicle is parked on a hill. Always block the wheels to prevent rolling.

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.

WARNING

Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.

Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

The auxiliary foot brake is located on the inside of the right footrest. Operate this brake with your right foot.

NOTE: If the rear wheels slide

Check the brake fluid level frequently for the auxiliary brake system. See page 71.

while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.

FEATURES AND CONTROLS

Fuel Tank

Cap

ON OFF

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 starting.

Fuel Tank Cap

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel.

Fuel Valve

The fuel valve is located on the bottom of the fuel tank. Access the fuel valve through the right front wheel well or from the front of the vehicle.

ON: For normal operation. OFF: For vehicle storage and

when transporting. Refuel when the instrument

gauge indicates a low fuel level.

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

FEATURES AND CONTROLS

Gear

Selector

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.

CAUTION

Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.

FEATURES AND CONTROLS

Recoil Starter

Handle

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.

2. Pull slowly so you can feel

the engine strokes.

NOTE: The rope will be harder to pull when the engine is on a compression

3. Allow the recoil rope to rewind into the recoil assembly, then pull

4. Repeat all steps until the engine starts.

5. Make sure the handle is fully seated on the housing.

Extending the recoil starter rope until it stops can cause damage to the recoil assembly. Do not extend the starter rope so far that it stops.

If the starter rope handle is not seated properly, water may enter the recoil housing and damage components. Make sure the handle is fully seated on the recoil housing, especially when traveling in wet areas.

stroke. When a compression stroke is found, continue pulling the rope just until the engine rolls past the stroke, then stop pulling immediately.

the rope abruptly and forcefully to start the engine.

CAUTION

FEATURES AND CONTROLS

AWD

Switch

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 on.

When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.

NOTE: The override switch allows activation of AWD in reverse if the AWD

There is no limit to the length of time the vehicle may remain in AWD.

Engaging AWD

The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.

Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.

switch is on. See page 20.

CAUTION

Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest.

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. Refer to page 20 for additional information.

CAUTION

High water pressure may damage vehicle components. Wash this vehicle by hand or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.

Miles/Kilometers Toggle

The display in the tripmeter, odometer and speedometer can be changed to display either kilometers or miles.

1. To change modes, press and release the mode button (see page 31)

as often as needed to reach the odometer mode.

2. In the odometer mode, press and hold the mode button until the let-

ters flash, then release the button.

3. Press and release the button one more time. When the display stops

flashing, the mode has been set.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for 3 seconds at start-up.

1. Gear Indicator - This

indicator displays gear shifter position. N = Neutral (Green) R = Reverse (Amber)

2. Engine Hour Display

Indicator

3. Speedometer

4. Odometer/Tripmeter/

Hour Meter

Modes

Use the reverse override/mode button to toggle through the 3 standard modes.

NOTE: If using the mode button to program the rider information center, or to

Odometer

The odometer records the distance traveled by the vehicle.

Trip M eter

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 decimal point, but the odometer displays without a decimal point.

Hour Meter

This mode logs the total hours the engine has been in operation.

toggle through the options, the transmission cannot be in reverse.

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.

• Turn the fuel valve off whenever the vehicle is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

OPERATION

Break-In Period

The break-in period for your new Polaris 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 procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

Install the accessory oil cooler when the following conditions exist:

• The vehicle will be used for towing heavy loads.

• The vehicle will be used for dragging ground surfaces or performing similar activities.

• The vehicle is normally operated when the air temperature is above 100° F. (3 8 ° C).

CAUTION

Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.

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 necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

4. 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 35.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20 hours.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

OPERATION

Pre-Ride Checklist

WARNING

If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition.

Item Remarks Page

Brake system/lever travel Ensure proper operation 23

Brake fluid Ensure proper level 70

Auxiliary brake Ensure proper operation 25

Front suspension Inspect, lubricate if necessary 59

Rear suspension Inspect, lubricate if necessary 59

Steering Ensure free operation -

Tires Inspect condition and pressure 75

Wheels/fasteners Inspect, ensure fastener tightness 75

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 26

Coolant level (if applicable) Ensure proper level -

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 22

Indicator lights/switches Ensure operation 20

Engine stop switch Ensure proper operation 21

Air filter, pre-filter Inspect, clean 78

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

Brake light/tail lamp Check operation, apply Polaris dielec-

Riding gear Wear approved helmet, goggles, and

tric grease when lamp is replaced

protective clothing

104

21 80

OPERATION

Choke

Knob

Starting the Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

1. Position the vehicle on a level surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

NOTE: The starter interlock will prevent the engine from starting if the trans-

4. Turn the fuel valve on.

5. Sit on the vehicle.

NOTE: Do not use the choke if starting a warm engine. Excessive use of the

6. If the engine is cold, pull the

NOTE: The variable choke is fully

7. Move the engine stop switch to RUN.

NOTE: Do not press the throttle while starting the engine.

mission is in gear and the brake is not engaged.

choke can cause the spark plug to become wet fouled.

choke knob out until it stops.

on when the knob is pulled completely out. The choke is off when the knob is pushed completely in. The choke can be adjusted gradually, depending on how much choke is needed for starting. Be sure the choke is off during operation, as excess fuel washing into the engine oil will increase wear on engine components.

OPERATION

Starting the Engine

8. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

9. If the engine does not start, return the key to the OFF position and wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

NOTE: If a warm engine has cooled to a point where it does not readily start,

10. If the engine slows or stops, position the choke knob half way in to

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

Cold Weather Operation

If this vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

intermittent use of the choke button (pulled half way out) may be necessary. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in starting. Release the throttle lever immediately after the engine starts. If the engine does not start and all conditions are favorable, change the spark plug and try again.

allow proper engine warm up. Vary the engine RPM slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke completely in.

CAUTION

OPERATION

1/3

2/3

Maximum

6 3/4" (17 cm)

Hauling Cargo

Your vehicle has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decals.

Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Do not obstruct the headlight beam with cargo.

Towing Loads

Always attach a towed load to the hitch point. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity.

CAUTION

Using an improper hitch or exceeding the maximum tongue weight capacity can 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 vehicle. Always install Polarisapproved (or equivalent) accessories designed for use on your vehicle.

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.

CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on only one rack increases the possibility of vehicle overturn.

CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

OPERATION

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. Check your surroundings and determine your path of travel.

6. Release the parking brake.

7. Slowly depress the throttle with your right thumb and begin driving.

8. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

OPERATION

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.

To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to turn at

faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds.

OPERATION

Driving Safely

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:

1. Slow down when entering slippery areas.

2. Engage AWD before wheels begin to lose traction.

3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

4. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

CAUTION

Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the rear wheels to stop spinning before engaging AWD, or engage AWD before wheels begin to lose traction.

WARNING

Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death.

Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.

OPERATION

25° Maximum

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. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.

WARNING

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (25° maximum).

Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual.

OPERATION

Driving Safely

Driving on a Sidehill (Sidehilling)

WARNING

Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.

Sidehilling can be dangerous and should be avoided if at all possible. If you encounter a situation where sidehilling is necessary, follow these precautions:

1. Slow down.

2. Shift your weight uphill.

3. Keep your feet on the footrests.

4. Steer slightly into the hill to maintain vehicle direction.

NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if pos-

sible, or dismount on the uphill side immediately!

OPERATION

Driving Safely

Driving Downhill

WARNING

Excessive speed when traveling downhill can cause loss of control and serious injury or death. Slow down.

Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control and serious injury or death. Apply the brakes gradually.

When driving downhill, follow these precautions:

1. Shift your weight uphill.

2. Drive straight downhill.

3. Slow down.

4. Squeeze the brake lever gradually.

NOTE: Before operating your vehicle, learn how to use the auxiliary brake for

emergency situations (if single-lever brakes become inoperable).

OPERATION

8 ft. (2.4 m)

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.

OPERATION

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 vehicle is pointing straight uphill.

4. Staying uphill of the vehicle, turn the handlebars full left.

5. While holding the brake lever, release the parking brake lock and slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

6. Lock the parking brake. Remount the vehicle from the uphill side, keeping body weight uphill.

7. Start the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed with the brake lever, until the vehicle is on more level ground.

OPERATION

Maximum Depth

Driving Safely

Driving Through Water

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. Proceed slowly, avoiding rocks and obstacles.

4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.

OPERATION

Driving Safely

Driving Through Water

After running the vehicle in water, it's critical to have it serviced as outlined 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.

CAUTION

Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart.

If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you

cannot avoid water that exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

If your vehicle becomes immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 84. Have the vehicle serviced by your dealer at the first opportunity.

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.

WARNING

Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.

OPERATION

Driving Safely

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.

6. Never open the throttle suddenly.

WARNING

Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.

Do not use the override switch unless additional power is required for vehicle movement. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: Your Polaris 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.

CAUTION

Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage. Operate the throttle just enough to maintain a desired speed.

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. Turn the fuel valve off.

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.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.

Electromagnetic Interference

This spark ignition system complies with USA requirements, Canadian ICES-002 and European directives 89/336/EEC and 97/24/EC.

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on page 117.

NOTE: Service and adjustments are important for proper vehicle operation. If

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour (16 km/h). Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold

weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

X 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.)

Q Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Q Steering - Pre-Ride - Make adjustments as need

X Front suspension - Pre-Ride - X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride - X Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride - XEAir filter, pre-filter - Daily - Inspect; clean often; replace

X Air box sediment

tube

Headlamp/tail lamp

XEAir filter,

main element

Recoil housing (if applicable)

Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test

X Front gearcase oil

(if equipped)

X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly XEEngine breather

filter (if equipped)

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

- Daily - Drain deposits when visible

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

- Weekly - Drain water as needed,

25 H Monthly 250 (400) Inspect level; change yearly

25 H Monthly 250 (400) Inspect; clean if needed

(Km)

ed. See Pre-Ride Checklist on page 35.

as needed

dielectric grease if replacing

check often if operating in wet conditions

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

X General

lubrication

Carburetor float bowl

Throttle Cable/

ETC Switch

Choke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;

E Carburetor air

intake ducts/flange

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as

X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change

X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change X Oil tank vent hose

(if equipped)

Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust

Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,

X Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

Ignition Timing 100 H 12 M 1000 (1600) Inspect

X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

(whichever comes first)

Hours Calendar Miles

50 H 3 M 500 (800) Lubricate all fittings, pivots,

50 H 6 M 500 (800) Drain bowl periodically and

50 H 6 M 500 (800) Inspect; adjust; lubricate;

50 H 6 M 500 (800 Inspect duct for proper seal-

100 H 6 M 1000 (1600) Inspect routing, condition

100 H 12 M 1000 (1600) Inspect

(Km)

cables, etc.

prior to storage

replace if necessary

ing/air leaks

needed

at 20 hours

lines, fuel valve, filter, pump, carburetor; replace lines every two years

security; apply dielectric grease to connectors subjected to water, mud, etc.

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

Q Clutches (drive

and driven)

Q Front wheel

bearings

Q Brake fluid 200 H 24 M 2000 (3200) Change every two years

Spark arrestor 300 H 36 M 3000 (4800) Clean out

Idle speed - Adjust as needed

Q Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

100 H 12 M 1000 (1600) Inspect; clean; replace worn

100 H 12 M 1000 (1600) Inspect; replace as needed

(Km)

parts

when parts are replaced

Remarks

MAINTENANCE

Front Prop Shaft Yoke

Bearing

Carrier

Control Arms

Transmission Upper

Pivot Point

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Items not listed in the chart should be lubricated at the General Lubrication interval.

Item Lube Method

Engine Oil PS-4 PLUS Performance

Brake Fluid DOT 4 Only See page 70.

Transmission Oil Polaris AGL Synthetic

Front Demand Drive Unit (Front Gearcase) (if equipped)

Front Prop Shaft Yoke

Control Arm (front and rear)

Bearing Carrier

Transmission (upper pivot point)

Synthetic 2W-50

Gearcase Lube

Premium Demand Drive Hub Fluid

Polaris Premium U-Joint Lube

See page 60.

See page 64.

See page 67.

Grease fittings (3 pumps maximum) every 500 miles (800 km), before long periods of storage, or after pressure washing or submerging.

MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing 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 temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Oil Specifications

Lubricant Capacity Drain Plug Torque

PS-4 PLUS Performance

Synthetic 2W-50

2 qts. (1.9 l) 14 ft. lbs. (19 Nm)

MAINTENANCE

Dipstick

Safe

Add Oil

Safe Range

{

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. Stop the engine.

5. Remove the dipstick.

Wipe it dry with a clean cloth.

6. Reinstall the dipstick

completely.

7. Remove the dipstick and check the oil level. Add oil as needed.

Maintain the oil level in the safe range. Do not overfill.

8. Reinstall the dipstick.

MAINTENANCE

Oil and Filter Change

CAUTION

Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin.

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

4. Start the engine. Allow it to idle for two to three minutes. Stop the engine.

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. Reinstall the drain plug with a new sealing washer.

NOTE: The sealing surfaces on the drain plug and

10. Torque to specification. See page 60.

crankcase should be clean and free of burrs, nicks or scratches.

MAINTENANCE

Safe

Add Oil

Safe Range

{

Oil and Filter Change

11. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it.

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.

14. Install the new oil filter. After the filter contacts the engine surface, turn it 1/2 turn by hand.

15. Remove the dipstick.

16. Add the recommended oil. See page 60.

17. Reinstall the dipstick.

18. Start the engine. Allow it to idle for two minutes.

19. Stop the engine.

20. Check for oil leaks.

21. Remove the dipstick and check the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill.

22. Reinstall the dipstick.

23. Discard used oil and filter properly.

MAINTENANCE

Drain Plug

Fill Plug

Transmission Oil

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page

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.

Transmission Oil Recommendations

Gearcase Lubricant Capacity Fill Plug

Transmission

2x4

Transmission

4x4

Premium AGL Synthetic

Gearcase Lubricant

Premium AGL Synthetic

Gearcase Lubricant

15.2 oz. (450 ml)

20.3 oz. (600 ml)

To r q u e

15 ft. lbs.

(20 Nm)

15 ft. lbs.

(20 Nm)

Drain Plug

To r q u e

15 ft. lbs.

(20 Nm)

15 ft. lbs.

(20 Nm)

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.

7. Reinstall the fill plug. Torque to specification. See page 64 for recommendations.

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.

6. Remove the drain plug. Use a 15 mm wrench.

7. Allow the oil to drain completely.

8. Clean and reinstall the drain plug. Torque to specification. See page 64 for recommendations.

9. Add the recommended oil.

10. Reinstall the fill plug. Torque to specification. See page 64 for recommendations.

11. Check for leaks.

12. Dispose of used oil properly.

MAINTENANCE

Drain Plug

Fill Plug

Fill Level

Front Gearcase (Demand Drive) Fluid (if equipped)

Always check and change the demand drive fluid at the intervals outlined in the 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 components. See page 105 for the part numbers of Polaris products.

Maintain the fluid level at the bottom of the fill hole threads. The fill plug is located on the right side of the gearcase. The drain plug is located on the bottom right side of the gearcase.

Demand Drive Fluid Recommendations

Gearcase Lubricant Capacity Fill Plug

Demand

Drive Unit

(if equipped)

Premium Demand Drive

Hub Fluid

5 oz.

(148 ml)

To r q u e

8-10 ft. lbs. (11-13 Nm)

Drain Plug

To r q u e

8-10 ft. lbs. (11-13 Nm)

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. Check the oil level.

6. Add the recommended oil as needed to bring the level to the bottom of the fill hole threads.

7. Reinstall the fill plug. Torque to specification. See page 67.

MAINTENANCE

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.

6. Remove the drain plug. Use an 11

mm wrench.

7. Allow the oil to drain completely.

8. Clean and reinstall the drain

plug. Torque to specification. See page 67.

9. Add the recommended fluid.

10. Reinstall the fill plug.

Torque to specification.

11. Check for leaks.

12. Dispose of used oil properly.

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.

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

If the fluid level is low add DOT 4 brake fluid only. See page 105 for the part numbers of Polaris products.

WARNING

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

Brake Fluid

Master Cylinder

Indicator

Window

Minimum

Maximum

Full

Low

Hand Brake

The master cylinder is located on the left handlebar. Maintain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder. Do not overfill.

1. Position the vehicle on a level surface. Make sure the handlebars are straight.

2. View the fluid level

NOTE: The eye will appear

3. Add the recommended

Foot Brake

The brake fluid reservoir is located on the right side of the vehicle. Maintain the fluid level between the minimum and maximum marks. Do not overfill.

through the indicator window (eye) on the top of the master cylinder.

dark when the fluid level is full. When fluid is low, the eye will be clear.

fluid as needed. Do not overfill.

MAINTENANCE

.03" (.8 mm)

Brakes

The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting.

Brake Inspections

The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation.

1. Always keep brake fluid at an adequate level. See page 70.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or spongy feel.

4. Check the friction pads for wear, damage and looseness. Replace the pads when the friction material is worn to .03" (.8 mm).

5. Check the security and surface condition of the disc.

MAINTENANCE

String

Stand

Toe Alignment

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. Position the vehicle on a level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string

between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire.

NOTE: If available, you may

4. Measure the distance

5. Repeat the measurement procedure on the other side of the vehicle.

NOTE: If you discover improper alignment, see your Polaris dealer for service.

use a long straightedge instead of string.

from the string to the rim at the front (1) and rear (2) of the front rim. The rear measurement should be 2-3 mm more than the front measurement on each side of the vehicle to obtain the recommended 3-6 mm toe out alignment.

MAINTENANCE

Screws

Rivets

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.

2. Grasp the top of the side panel and pull it outward to remove it.

Footwell Removal

1. Remove the two screws on the bottom of the footwell.

2. Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders.

3. Remove the footwell.

MAINTENANCE

1/8" (3 mm)

Tires

Refer to the specifications section beginning on page 110 for recommended tire type, size and pressure.

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 resulting in serious injury or death.

Maintain proper tire pressure as described on the decal on your vehicle and in the owner's manual.

Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8" (3 mm) or less.

Tire Tread Depth

Always replace tires 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 component operations. All service must be performed by your authorized Polaris dealer.

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.

6. Remove the wheel nuts.

7. Remove the wheel.

MAINTENANCE

90 ft. lbs. (122 Nm)

27 ft. lbs.

(37 Nm)

CAST ALUMINUM STEEL

Tires

Wheel Installation

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer.

1. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation.

2. Install the wheel nuts finger

tight.

3. Lower the vehicle to the ground.

4. Torque the wheel nuts to

specification.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loosened for service.

Nut Type Nut Torque

Lug Nut 90 ft. lbs. (122 Nm)

2-Piece Flange Nut 27 ft. lbs. (37 Nm)

MAINTENANCE

Air Filter

Clips

Breather

Filter

Sleeve

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. Remove the sleeve from the filter.

8. Wash the sleeve in soapy water, then rinse and let dry.

9. Remove the breather filter.

10. Wash the breather filter in soapy water, then rinse and let dry.

11. Reinstall the breather filter.

Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing it for service.

CAUTION

12. Reinstall the sleeve over the air filter. Replace the filter if needed.

13. Reinstall the air filter into the air box.

14. Reinstall the air box cover and the seat.

MAINTENANCE

25 ft.

(7.6 m)

2" (5 cm)

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 approximately 25 ft. (7.6 m) from a wall.

2. Place the transmission in neutral.

3. Lock the parking brake.

4. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height.

NOTE: Include rider weight on the seat when measuring.

5. Start the engine.Turn the headlight switch to high beam.

6. Observe the headlight aim on the wall. The most intense part of the

headlight beam should be two inches (5 cm) below the mark on the wall.

7. Loosen the phillips screw at the rear of the headlamp.

8. Adjust the beam.

9. Tighten the screw.

MAINTENANCE

Harness

Screw

Lamp

Cover

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.

WARNING

Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality.

Hot components can cause serious burns to skin. Allow lamps to cool before servicing.

Headlamp Replacement

1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly.

2. Remove the headlamp and install the new headlamp.

3. Reinstall the harness assembly into the headlight assembly.

4. Turn the headlight harness clockwise to secure the headlamp.

Taillight/Brakelight Lamp Replacement

1. From the rear of the brakelight, remove the two screws holding the lens cover in place. Remove the lens cover.

2. Remove the lamp and replace it with a new lamp.

3. Test the light for proper operation.

4. Reinstall the lens cover.

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 gear.

2. Lock the parking brake.

3. Stop the engine.

4. Remove the drain screw on the bottom of the recoil housing.

5. Reinstall the drain screw.

NOTE: Do not open the crankcase drain

unless the engine has ingested water. On 4-cycle engines, some engine oil will be lost if the crankcase drain is opened.

MAINTENANCE

Spark Plug

Spark Plugs

Spark Plug Recommendations

CAUTION

Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.

Refer to the specifications section beginning on page 110 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

Plug Condition Torque Specification

New Spark Plug 9-11 ft. lbs. (12-15 Nm)

Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 83.

WARNING

A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection.

1. Remove the left side panel.

2. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.

3. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove it.

MAINTENANCE

Spark Plugs

Spark Plug Inspection

4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before 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. 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 flaky and white. A white insulator tip indicates

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect throttle body/carburetor adjustments.

overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

MAINTENANCE

Drain

Screw

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle out of the water.

2. Turn the fuel valve off.

3. Check the air box. If water is present, dry the air box and replace the filter with a new filter.

4. Remove the spark plug.

5. Loosen the carburetor drain screw and drain the carburetor.

6. Turn the engine over several times using the electric start.

7. Dry the spark plug. Reinstall the plug or install a new plug.

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

10. Attempt to start the engine. If necessary, repeat the drying procedure.

11. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not.

12. If water has been ingested into the PVT, follow the procedure on page 87 for drying out the PVT.

MAINTENANCE

Exhaust

Outlet

Clean-Out Plug

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.

The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.

Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas. Never go under the vehicle while it's inclined.

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler.

1. Position the vehicle on a level surface.

2. Place the transmission in

neutral.

3. Lock the parking brake.

4. Remove the arrestor

clean-out plug from the bottom of the muffler.

5. Start the engine.

6. Quickly squeeze and release the throttle lever several times to purge

carbon from the system.

7. If carbon comes out of the exhaust, cover or plug the exhaust outlet.

Wear protective gloves.

8. Lightly tap on the exhaust pipe with a rubber mallet while repeating

step 6.

9. If particles are still suspected to be in the muffler, elevate the rear of

the vehicle one foot (30 cm) higher than the front. Block the wheels.

10. Place the transmission in neutral. Lock the parking brake. Repeat

steps 6 to 8 until no more particles are expelled.

11. Stop the engine. Allow the arrestor to cool.

12. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

MAINTENANCE

PVT System

WARNING

Failure to comply with the instructions in this warning can result in severe injury or death.

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual.

• This PVT system is intended for use on Polaris products only. Do not install it in any other product.

• Always make sure the PVT housing is securely in place during operation.

PVT System

PVT Drain

Plug

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.

3. Allow the water to drain com-

pletely. Reinstall the drain plug.

4. Start the engine. Place the trans-

mission in neutral.

5. Apply varying throttle for 10-15

seconds to expel the moisture and air-dry the belt and clutches.

NOTE: Do not hold the throttle wide

open for more than 10 seconds.

6. Allow the engine RPM to settle

to idle speed, then shift the transmission into forward gear.

7. Test for belt slippage. If the belt

slips, repeat the process.

8. Take the vehicle to your dealer

for service as soon as possible.

MAINTENANCE

Battery

Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

Conventional Battery

Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

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.

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.

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.

7. Disconnect the red (posi-

tive) battery cable last.

8. 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.

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 92 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).

NOTE: The vent tube must be free of obstructions and securely installed.

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

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Secure the battery hold-down strap.

8. Verify that cables are properly routed.

NOTE: Cables should be safely tucked away at the front and rear of the bat-

Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

WARNING

or petroleum jelly.

tery.

MAINTENANCE

Lower

Mark

Upper

Mark

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

Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks.

Add only distilled water. Tap water contains minerals that are harmful to a battery.

charger or by charging about once a month to make up for normal selfdischarge. 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 105 for the part numbers of Polaris products.

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leaking 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. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. See page 90. 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 installation 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.

WARNING

An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.

2. If the 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.

MAINTENANCE

Battery

Battery Charging (Sealed Battery)

NOTE: Always verify battery condition before and 1-2 hours after the end of

charging.

State of

Charge

100% 12.8-13.0 volts None, check at 3

75%-100% 12.5-12.8 volts May need slight

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,

0%-25% 11.5 volts or less Needs charge with

Voltage Action

mos. from date of

manufacture

charge, if no

charge given,

check in 3 months

desulfating charger

Charge Time

(Using constant current

charger @ standard amps

specified on top of battery)

None required

3-6 hours

verify state of charge

At least 20 hours

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components.

CAUTION

High water pressure may damage components. Polaris recommends 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.

The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• 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.

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 following items:

• Wheel bearings

• Transmission seals

•Brakes

• Cab and body panels

• Labels and decals

NOTE: If warning and safety labels are damaged, contact your Polaris dealer

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

• Avoid the use of automotive products, some of which can scratch the

• Always use clean cloths and pads for cleaning and polishing. Old or

for free replacement.

finish of your vehicle.

reused cloths and pads may contain dirt particles that will scratch the finish.

MAINTENANCE

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, preserve 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)

1. Wash chrome wheels frequently. Use a mild detergent. Never use

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

3. Polish the clean chrome wheels periodically. Use an automotive

4. Routinely and liberally apply a weather resistant wax to each pol-

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 outlined above.

are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements.

abrasive cleaners on plated or painted surfaces.

other elements can cause corrosion.

grade chrome polish.

ished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions.

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 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: Carbon Clean removes water from fuel systems, stabilizes fuel and

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to

4. Turn the fuel valve off.

5. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 62.

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 81.

removes carbon deposits from pistons, rings, valves and exhaust systems.

disperse through the fuel in the tank and carburetor.

MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 54.

• Demand drive unit (front gearcase) (if equipped)

• Transmission

• 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 97.

2. Support the front end of the machine so the engine is level or tilted

slightly rearward.

3. Remove the spark plug. Rotate the piston to BDC and pour two

ounces (59 ml) of engine oil into the cylinder.

4. Reinstall the spark plug. Torque to specification.

5. Apply dielectric grease to the inside of the spark plug cap. Reinstall

the cap.

6. Turn the engine over several times using the recoil starter. Oil will

be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

7. If Polaris fuel system additive is not used, the fuel tank, fuel lines,

and carburetor should be completely drained of gasoline.

Polaris Hawkeye 9922016 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual