Polaris Hawkeye 300 2X4, Hawkeye 9920788, Scrambler 4X4 International 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 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor 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. 2007 Hawkeye 2X4/Hawkeye 4X4 International Owner’s Manual P/N 9920788

TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Features and Controls . . . . . . . . . . . . . . . . . . . 34

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Emission Control Systems . . . . . . . . . . . . . . . 52

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 107

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 108

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 112

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 119

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

KNOW YOUR VEHICLE

As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable 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.

VIN

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

####

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. A Polaris Quadricycle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

Read and understand your owner's manual and all warnings before operating a Polaris Quadricycle.

Safety Training

When you purchased your new Quadricycle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis.

If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

Restrictions

This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited.

Equipment Modifications

The warranty on your Polaris Quadricycle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.

NOTE: The addition of certain accessories, including (but not limited to) mow-

ers, blades, tires, sprayers and large racks may change vehicle 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 the Quadricycle.

Never operate a Quadricycle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or call Polaris at 1-800-342-3764.

Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

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

Never carry a passenger. The purpose of the long seat is to allow the operator to shift position.

SAFETY

Operator Safety

Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

Never consume alcohol or drugs before or while operating a Quadricycle.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

Never attempt jumps or other stunts.

Operator Safety

Always inspect your Quadricycle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 49.

Keep both hands on the handlebars. Keep your feet on the footrests.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

SAFETY

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

Always follow the procedures outlined in this manual for turning. See page

19. Never turn sharply at excessive

speeds, which can lead to vehicle overturn.

SAFETY

Operator Safety

If a Quadricycle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

Never operate on hills too steep for the Quadricycle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°.

Always follow the procedures outlined in this manual for climbing hills. See page 22.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 25.

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 24.

Never attempt to turn the Quadricycle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

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 26.

Always follow the procedures outlined in this manual for operating over obstacles. See page 21.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 20.

SAFETY

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 28.

SAFETY

Operator Safety

Always follow the procedures outlined in this manual for driving in reverse. See page 31.

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

Never modify a Quadricycle through improper installation or use of accessories.

Never exceed the stated load capacity for your Quadricycle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

Operator Safety

Never operate the Quadricycle on a frozen body of water.

Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control, accident, and/ or injury. Avoid sudden turns or swift movement of the handlebars.

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

SAFETY

Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

For more information about Quadricycle safety,

call Polaris at 1-800-342-3764.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

The following pages repeat the information found on each decal.

General Alert (Multi-Lingual)

Before you operate this vehicle, read the owner’s manual.

General

Alert

Hill Operation Alert

• Never operate this vehicle on HILLS steeper than 25 degrees 25°.

• To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.

Age 16

Alert

Hill Operation

Alert

Safety Decals and Locations

SAFETY

Rack

Warning

“No Passenger” Warning

WARNING NEVER ride as a passenger. Passengers can cause a loss

of control, resulting in SEVERE INJURY or DEATH.

Tire Pressure/Load Alert

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 930 LBS. (423 kg). Read Owner's Manual for more detailed loading information.

Rack

Warning

“No Passenger”

Warning

Tire Pressure/

Load Alert

Rack Warning, Front and Rear

WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may

result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 70 lbs. (32 kg) Rear 100 lbs. (46 kg)

Reverse Override Alert (4X4 Models)

Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner's Manual.

SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Eye Protection

Helmet

Boots

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.

Long

Sleeves

Gloves

Long Pants

051039

0006.31

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.

SAFETY

Driving Safely

Driving Procedures

1. Sit upright. Keep your feet on the footrests. Keep both hands on the

handlebars.

2. Apply the brakes.

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 brakes.

7. Slowly squeeze the throttle lever toward the handlebar to begin

driving.

8. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

Driving Safely

Turning the Vehicle

1. Before turning, activate a turn

signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn.

2. Steer in the direction of the

turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse.

3. Practice turning at slow speeds

before attempting to turn at faster speeds.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

SAFETY

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

SAFETY

Driving Safely

Driving on Slippery Surfaces

Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:

1. Slow down before driving

onto slippery surfaces.

2. Engage AWD before wheels

begin to lose traction (4x4 models).

3. Be alert.

4. Watch the trail.

5. Avoid quick, sharp turns.

NOTE: To correct a rear wheel

Severe damage to the drive train may occur if AWD is engaged while the wheels are spinning. Engage AWD when the wheels have traction.

skid, turn the handlebars in the same direction as the skid and shift body

weight forward.

CAUTION

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding.

SAFETY

Driving Safely

Driving Over Obstacles

1. Always check for obstacles before operating in a new area. Serious

injury or death can result if your vehicle comes in contact with a hidden obstacle.

2. Be alert. Watch the terrain. Use extra caution.

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

Always follow the procedures outlined in this manual for operating over obstacles.

SAFETY

Driving Safely

Driving Uphill

25° Maximum

Whenever traveling uphill, follow these precautions:

1. Avoid steep hills (25° maximum).

2. Check the terrain carefully.

3. Avoid hills with excessively slippery or loose surfaces.

4. Shift your weight uphill.

5. Drive straight uphill.

6. Keep your feet on the footrests.

7. Drive at a steady rate of speed to avoid stalling.

8. Be alert. Be prepared to take emergency action. This may

include dismounting quickly.

9. Never open the throttle suddenly or make sudden gear changes.

10. Never go over the top of a hill at high speed.

SAFETY

Driving Safely

Driving Uphill

If all forward speed is lost:

Keep your weight uphill.

If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards.

Apply the brakes gradually. When fully stopped, lock the hydraulic parking brake. See page 39.

Dismount on the uphill side, or to either side if the vehicle is pointed straight uphill. Turn the vehicle around using the K-Turn. See page 26.

Always follow the procedures outlined in this manual for climbing hills. Avoid climbing hills steeper than 25°.

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.

SAFETY

Driving Safely

Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:

1. Slow down.

2. Avoid hills with excessively slippery or loose surfaces.

3. Shift your weight uphill.

4. Avoid crossing the sides of steep hills.

5. Keep your feet on the footrests.

6. Steer slightly into the hill.

NOTE: If the vehicle begins to tip, quickly turn the front wheels downhill (if

possible) or dismount on the uphill side immediately!

Always follow the procedures outlined in this manual for crossing the side of a hill.

Never attempt to turn the Quadricycle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

Driving Safely

Driving Downhill

When driving downhill, follow these precautions:

1. Check the terrain carefully.

2. Avoid hills with

excessively slippery or loose surfaces.

3. Never drive downhill at

high speed.

4. Slow down.

5. Avoid driving downhill at

an angle, which can cause the vehicle to pitch sharply to one side. Drive straight downhill.

6. Shift your weight rearward.

7. Apply the brakes slightly to aid in slowing.

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

SAFETY

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

SAFETY

Driving Safely

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

2.4 m

1. Stop the vehicle. Keep your weight uphill.

2. Lock the hydraulic parking brake.

3. Leave the transmission in forward gear. Turn the engine off.

4. Dismount on the uphill side of the vehicle, or on the left if the vehi-

cle is pointing straight uphill.

5. Stay uphill of the vehicle and turn the handlebars full left.

6. Squeeze the brake lever to release the parking brake.

7. Slowly release the brake lever and allow the vehicle to roll around

to your right until it's pointing across the hill or slightly downward.

SAFETY

Driving Safely

Turning Around on a Hill (K-Turn)

8. Lock the hydraulic parking brake.

9. Remount from the uphill side. Keep your weight uphill.

10. Apply the foot brake.

11. With the transmission still in forward, start the engine.

12. Squeeze and release the brake lever to release the parking brake.

13. Release the foot brake and drive slowly downhill. Control speed

with either the hand or foot brake until the vehicle is on level ground.

Always follow the procedures outlined in this manual for climbing hills. See page 22.

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 24.

SAFETY

Driving Safely

Driving Through Water

Maximum Depth

Follow these procedures when driving through water:

1. Check water depth and current before crossing.

2. Avoid operating in water deeper than the bottom of the footrests. If

it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.

3. Choose a crossing where both banks have gradual inclines.

4. Drive slowly. Avoid rocks and obstacles.

5. Wet brakes may have reduced stopping ability. Always test your

brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.

SAFETY

Driving Safely

Driving Through Water

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

CAUTION

If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 85. Have the vehicle serviced by your dealer promptly.

NOTE: If water has been ingested into the transmission (PVT), follow the pro-

cedure on page 88.

SAFETY

Driving Safely

Parking on an Incline

Avoid parking on an incline. If it's unavoidable, follow these precautions:

1. Stop the engine.

2. Place the transmission in PARK.

3. Always block the rear wheels on the downhill side.

4. Turn the fuel valve off.

SAFETY

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Avoid backing down-

hill.

2. Always check for

obstacles or people behind the vehicle before backing.

3. Drive slowly.

4. Apply the foot brake

lightly for stopping.

5. Avoid turning at sharp

angles.

6. Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

NOTE: Reverse speed is greatly increased when the override switch is used.

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.

Do not operate at full throttle. Apply just enough throttle to maintain the desired speed.

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

SAFETY

Driving Safely

Hauling Cargo

WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo.

• Read and understand the load distribution warnings listed on the vehicle warning labels.

• Never exceed the stated load capacity for this vehicle.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes. Avoid situations that require backing downhill.

• When operating over rough or hilly terrain, reduce speed, cargo and towed load to maintain stable driving conditions.

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

• CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. Reduce load weight when cargo is high. Secure off-centered loads that cannot be centered and operate with extra caution.

• CARRYING A LOAD on only one rack may cause the vehicle to overturn. Split the load between the front rack and rear rack, with 1/3 in the front and 2/3 in the back. Do not exceed load capacities. See specifications beginning on page 112.

• 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.

• 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.

• TOWING is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when towing loads in rough terrain, while cornering, or while ascending or descending hills.

SAFETY

Driving Safely

Hauling Cargo

2/3

1/3

Towing Loads

Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15°.

Maximum Towed Load

(Level Ground)

386 kg 38.6 kg

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 Quadricycle. Always install Polaris-approved (or equivalent) accessories designed for Quadricycle use.

Maximum Vertical Hitch

Weight

Maximum

6 3/4" (17 cm)

FEATURES AND CONTROLS

Switches

Mode/Reverse

Override Switch

Main Key

Switch

Headlight

Switch

Engine

Stop Switch

All Wheel Drive

Switch

Mode/Reverse Override Switch

Press the switch to toggle through the speedometer display modes (except in reverse). See page

45.

To gain additional power while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse speed limit function.

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

reverse, if the AWD switch is on.

WARNING

Activating the override switch with the throttle open and while operating in reverse can cause loss of control. Do not activate the override switch while the throttle is open.

FEATURES AND CONTROLS

Switches

Main Key Switch

End all electrical power to the vehicle.

LIGHTS ON position turns the headlights on.

Start the engine. The headlights are not on in this position.

After starting the engine, release the key switch to the POSITION LIGHTS ON position.

WARNING

Do not attach a large key fob or key ring to the main switch. It may contact the gas tank cap when turning, causing an interruption to the electrical system and an unexpected engine shut-down during operation. This could result in serious injury or death.

Engine Stop Switch

The engine will not start or run when

Engine

Stop Switch

the switch is in the OFF position.

OFF

RUN

Light Switch

The lights do not operate unless the main key switch is on and the engine

Light

Switch

stop switch is in the RUN position. An indicator light on the pod will illuminate when high beam is selected. See page 36.

High Beam

Low Beam

FEATURES AND CONTROLS

Switches

All Wheel Drive Switch (4x4 Models)

See page 44 for all wheel drive information.

AWD Switch

Hazard Warning Switch

Push the hazard warning switch to

cause all turn indicators to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.

Turn Signal Switch

Push the toggle switch either left or right to activate the corresponding

turn signal. The indicator on the console will also flash. Return the toggle to the center position and push it inward to end the signal.

Horn Switch

Hazard

Switch

Horn

Switch

High Beam

Indicator

Turn Indicators

Turn Signal

Switch

Press the horn switch to sound the horn.

FEATURES AND CONTROLS

Throttle Lever

Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement.

WARNING

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.

Do not start or operate a Quadricycle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

Choke

The choke assists in starting a cold engine. See page 50.

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the Quadricycle.

Choke

Knob

Electronic Throttle Control (ETC)

ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.

Electronic Throttle Control

FEATURES AND CONTROLS

Foot Brake

The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to engage the all-wheel brakes.

If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.

Hand Brake Lever

The hand brake operates both front and rear brakes. Squeeze the brake lever toward the handlebar to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using this brake, reduce lever pressure.

WARNING

Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control.

Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes.

Foot Brake

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in PAR K.

2. Squeeze the brake lever toward

the handlebar.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake

lock, squeeze and release the brake lever.

WARNING

Operating the Quadricycle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.

FEATURES AND CONTROLS

Steering Lock

Lock the steering to prevent unauthorized use or theft of the vehicle.

1. Turn the handlebars to the full left position.

2. Insert the steering lock key and turn it clockwise.

3. Remove the key.

4. Reverse the procedure to unlock the steering.

NOTE: Place the steering lock keys in a safe place. The lock must be

replaced if the keys are lost.

FEATURES AND CONTROLS

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 of 87. Do not use E-85

fuel.

Fuel Valve

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

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.

Fuel Tank

Cap

ON OFF

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector is located on the right side of the vehicle.

H: High Gear N: Neutral R: Reverse P: Park

Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PAR K.

Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage. Stop the vehicle, release the throttle and move the shift lever to the desired gear. See your dealer if you experience any shifting problems.

Gear Selector

CAUTION

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 50, cranking the engine with the recoil starter instead of the main key switch.

1. Grasp the recoil starter rope handle tightly.

2. Pull slightly until the starter

mechanism engages.

3. Pull the rope abruptly to start

the engine.

CAUTION

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

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.

Handle

Recoil Starter

FEATURES AND CONTROLS

All Wheel Drive (AWD) System (4X4 Models)

The AWD switch may be turned on or off while the vehicle is moving. AWD will not engage until engine speed is below 3100 RPM. AWD remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in AWD.

If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction. Engage AWD before getting into situations where maximum traction is needed. If the rear wheels are spinning, release the throttle before switching to AWD.

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

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.

AWD

When the AWD switch is on, the Quadricycle is in fourwheel drive and the differential is locked, providing maximum traction. The demand drive unit automatically engages when the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit automatically disengages.

switch is on. See page 34.

CAUTION

2X4

When the 2X4 switch is on, the Quadricycle is in twowheel drive at all times and the differential is locked.

FEATURES AND CONTROLS

Instrument Cluster

The instrument cluster measures distance in kilometers (or miles) as well as hours of operation. It also includes a reverse speed limiter function that limits vehicle speed to approximately 11-14 km/h. Refer to page 34 for additional information.

CAUTION

To prevent damage, wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster. Do not allow insect sprays to contact the lens.

Miles/Kilometers Toggle

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

1. To change modes, press and release the mode button (see page 31) as often as needed to reach the odometer mode.

2. 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 once. 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

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

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.

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Use extreme caution whenever handling gasoline.

• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.

• Never fill a fuel container while it's on the vehicle. Static electricity between the rack and container could cause a spark.

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

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

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

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

OPERATION

Break-In Period

The break-in period for your new Polaris Quadricycle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and performance of your Quadricycle more than 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.

Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Install the accessory oil cooler when the following conditions exist:

• 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).

Engine and Drivetrain Break-in

1. Fill the fuel tank with the recommended fuel. See page 41.

2. Check the oil level. See page 60. Add oil if necessary.

3. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

4. Drive slowly. Vary the throttle positions. Do not operate at sustained

idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 49.

6. Pull only light loads.

7. Change the oil and filter at one month.

PVT Break-in (Clutches/Belt)

Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

OPERATION

Pre-Ride Checklist

Item Remarks Page

Foot brake Ensure proper operation 38

Hand brake/lever travel Ensure proper operation 38

Brake fluid Ensure proper level 70

Front suspension Inspect, lubricate if necessary 58

Rear suspension Inspect, lubricate if necessary 58

Steering Ensure free operation -

Tires Inspect condition and pressure 76

Wheels/fasteners Inspect, ensure fastener tightness 76

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 41

Throttle Ensure proper operation 37

Indicator lights/switches Ensure operation 34

Engine stop switch Ensure proper operation 35

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

106

OPERATION

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.

CAUTION

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

1. Position the vehicle on a

level surface.

2. Place the transmission in

PAR K.

________________________________________________________

3. Turn the fuel valve on.

4. Sit on the vehicle.

NOTE: Do not use the choke if starting a

5. If the engine is cold, pull the choke

NOTE: Make sure the choke is off during operation. Excess fuel washing into

________________________________________________________

6. Move the engine stop

NOTE: Do not press the throt-

________________________________________________________

warm engine. Excessive use of the choke can cause the spark plug to become wet fouled.

knob out until it stops.

the engine oil will increase wear on engine components.

switch to RUN.

tle while starting the engine.

OPERATION

Starting the Engine

7. Turn the ignition key past the POSITION

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

8. If the engine does not start, release the

starter and wait five seconds.

9. Repeat steps 7 and 8 until the engine starts.

NOTE: If a warm engine has cooled and does not readily start, intermittent

10. If the engine slows or stops after

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

use of the choke (HALF ON) may be necessary. If the engine is overchoked 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.

starting, move the choke knob

FULL ON

to HALF ON. Vary engine RPM slightly with the throttle.

HALF ON

When the engine idles smoothly, push the choke all the

OFF

way in.

CAUTION

Cold Weather Operation

Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the oil tank, which can lead to engine damage. Any condensation must be drained.

Always operate the engine long enough to reach operating temperature, which reduces condensation. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in cold weather.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

Spark Arrestor

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

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.

MAINTENANCE

Periodic Maintenance Chart

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

Record maintenance and service in the Maintenance Log beginning on page 119.

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

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

Steering - Pre-Ride - Make adjustments as need

Front suspension - Pre-Ride -

Rear suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake lever - Pre-Ride -

Foot brake - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

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 Demand drive unit

oil (front gearcase)

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 49.

as needed

dielectric grease if replacing

check often if operating in wet conditions

Remarks

MAINTENANCE

Periodic Maintenance Chart

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

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

Clutches (drive and driven)

Front wheel bearings

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

Toe adjustment - Inspect periodically; adjust

Brakes - Inspect daily; adjust as

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

needed

Remarks

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Items not listed in the chart should be lubricated at the General Lubrication interval.

Item Lube Method

Engine Oil Polaris Premium 4 Synthetic

Brake Fluid DOT 4 Only See page 70.

Transmission Oil Polaris AGL Synthetic

Front Demand Drive Unit (Front Gearcase)

Front Prop Shaft Yoke

Control Arm (front and rear)

Bearing Carrier

Transmission (upper pivot point)

0W-50

Gearcase Lube

Premium Demand Drive Hub Fluid

Polaris Premium U-Joint Lube

See page 59.

See page 64.

See page 67.

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

Front Prop Shaft Yoke

Bearing

Carrier

Transmission Upper

Pivot Point

Control Arms

MAINTENANCE

Engine Oil

Oil Recommendations

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Always change the oil filter whenever changing oil. Change the oil more often if the vehicle is routinely subjected to:

• operation in dusty or wet conditions

• operation when air temperature is below -12° C.

• short trips at -12° to -1° C. (engine fails to reach operating tempera-

ture).

Polaris recommends the use of Performance Synthetic 4-Stroke (PS-4) 0W-50 oil for this engine. PS-4 is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.

Oil may need to be changed more frequently if Polaris oil is not used. Always use 0W-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 a recommended oil. Never substitute or mix oil brands.

Oil Specifications

Lubricant Capacity Drain Plug Torque

Performance Synthetic 4-Stroke (PS-4) 0W-50

1.9 liters 19 N-m

MAINTENANCE

Engine Oil

Oil Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for 30 seconds.

4. Stop the engine.

5. Remove the dipstick.

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.

Safe Range

{

Add Oil

8. Reinstall the dipstick.

Safe

Dipstick

MAINTENANCE

Oil and Filter Change

CAUTION

Hot oil may result in serious burns. Do not allow hot oil to contact skin.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for two minutes.

4. Stop the engine.

5. Clean the area around

the drain plug.

6. Place a drain pan under

the vehicle.

7. Remove the drain plug.

Use a 6 mm Allen wrench.

8. Drain the oil.

9. Clean the drain plug. Reinstall the drain

plug with a new sealing washer.

10. Torque to specification. See page 59.

MAINTENANCE

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.

Oil and Filter Change

15. Remove the dipstick.

16. Add the recommended oil.

See page 59.

17. Reinstall the dipstick.

18. Start the engine. Allow it

to idle for two minutes.

19. Stop the engine.

20. Check for oil leaks.

MAINTENANCE

21. 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.

Safe Range

Add Oil

{

Safe

MAINTENANCE

Transmission Oil

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

53.

Use the recommended oil. Maintain the oil level at the bottom of the fill plug hole. See page 107 for the part numbers of Polaris products.

The fill plug is located on the left side of the vehicle, under the rear fender, behind the wheel. The drain plug is located behind the wheel well.

Transmission Oil Recommendations

Drain Plug

Fill Plug

Gearcase Lubricant Capacity Fill Plug

Transmission

2x4

Transmission

4x4

Premium AGL Synthetic

Gearcase Lubricant

Premium AGL Synthetic

Gearcase Lubricant

450 ml 20 N-m 20 N-m

600 ml 20 N-m 20 N-m

To r q u e

Drain Plug

To r q u e

Transmission Oil

Oil Check

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

Use a 15 mm wrench.

4. Check the oil level.

5. Add the recommended

oil as needed. Do not overfill.

6. Reinstall the fill plug.

Torque to specification. See page 64.

MAINTENANCE

Transmission Oil

Oil Change

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

Use a 15 mm wrench.

4. Place a drain pan under

the gearcase.

5. Remove the drain plug.

Use a 15 mm wrench.

6. Allow the oil to drain

completely.

7. Clean and reinstall the drain

plug. Torque to specification. See page 64.

8. Add the recommended oil.

9. Reinstall the fill plug.

Torque to specification. See page 64 for recommendations.

10. Check for leaks.

11. Dispose of used oil properly.

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.

Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 107 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

Fill Plug

Fill Level

Drain Plug

Gearcase Lubricant Capacity Fill Plug

Demand Drive

Unit

Premium Demand Drive

Hub Fluid

148 ml 11-13 N-m 11-13 N-m

To r q u e

Drain Plug

To r q u e

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Check

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug. Use

an 8 mm Allen wrench.

4. Check the fluid level.

5. Add the recommended

fluid as needed.

6. Reinstall the fill plug.

7. Torque to specification.

See page 67.

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Change

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug. Use an 8

mm Allen wrench.

4. Place a drain pan under the

gearcase.

5. Remove the drain plug. Use an 11

mm wrench.

6. Allow the oil to drain completely.

7. Clean and reinstall the drain

plug. Torque to specification. See page 67.

8. Add the recommended fluid.

9. Reinstall the fill plug.

Torque to specification.

10. Check for leaks.

11. Dispose of used oil properly.

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.

WARNING

Operating the Quadricycle with a spongy brake can result in loss of braking, which could cause an accident. Never operate the Quadricycle with spongyfeeling brakes.

If the fluid level is low add DOT 4 brake fluid only. See page 107 for the part numbers of Polaris products.

WARNING

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

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

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.

Brake Fluid

Hand Brake

The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill.

MAINTENANCE

Master Cylinder

Indicator Window

1. Position the vehicle on a

level surface. Make sure the handlebars are straight.

2. View the fluid level

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

NOTE: The eye will appear dark

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

3. Add the recommended fluid as needed. Do not overfill.

Full

Low

MAINTENANCE

Brake Fluid

Foot Brake

The brake fluid reservoir is located near the foot brake. Maintain the fluid level between the minimum and maximum marks. Do not overfill.

Maximum Minimum

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc brakes, activated by applying either the hand brake or the foot brake. Both brake systems are selfadjusting.

Brake Inspections

Perform the following checks to keep the brake systems 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 systems regu-

larly for fluid leaks.

3. Check the brakes for excessive

travel or spongy feel.

4. Check the friction pads for

wear, damage and looseness. Replace the pads when the friction material is worn to .8 mm.

5. Check the security and surface

condition of the disc.

.8 mm

MAINTENANCE

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. Place the handlebars

in a straight-ahead position.

2. Place stands in front

of the vehicle, perpendicular to the rear tires.

3. Tie an elastic string

around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle.

4. Measure the distance

from the string to the rim at the front and rear of the front rim. Rear measurement should be 2-3 mm more than the front measurement.

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

String

Rear of Front Rim

Front of Front Rim

Stands

MAINTENANCE

Steering Assembly

Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.

Side Panel Removal

1. Remove the seat.

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

Footwell Removal

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.

Screws

Rivets

MAINTENANCE

Tires

Refer to the specifications section beginning on page 112 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.

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

Use only original equipment size and type when replacing tires. Make sure the wheels are installed properly. Replace tires when the tread depth measures 3 mm or less.

Tire Tread Depth

Always replace tires when tread depth is worn to 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.

3 mm

Wheel Nut Torque Specifications

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

Item Specification

Front Wheel Nuts 27 ft. lbs. (37 N-m)

Rear Wheel Nuts 27 ft. lbs. (37 N-m)

MAINTENANCE

Tires

WARNING

Operating with improperly installed wheels will affect vehicle handling and could cause an accident resulting in serious injury or death. Always use original equipment size and type when replacing tires. Install wheels properly.

Wheel Removal/Installation

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Loosen the wheel nuts slightly.

4. Place a suitable stand under the

footrest frame to raise the wheel slightly off the ground.

5. Remove the wheel nuts.

6. Remove the wheel.

7. Place the wheel on the

hub.

8. Install the wheel nuts

finger tight.

9. Lower the vehicle to

the ground.

10. Torque the wheel nuts

to specification. See page 76.

MAINTENANCE

Air Filter/Breather Filter

Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the seat.

4. Release the air box

Sleeve

Clips

cover clips, and remove the air box cover.

5. Remove the air filter.

6. Remove the sleeve from

the filter.

7. Wash the sleeve in soapy

Air Filter

Breather

Filter

water, then rinse and let dry.

8. Remove the breather fil-

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

9. Reinstall the breather filter.

CAUTION

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

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

11. Reinstall the air filter into the air box. Tighten the clamp. Do not

over-tighten the clamp, as filter damage could occur.

12. Reinstall the air box cover and the seat.

MAINTENANCE

Lights

Headlight Beam Adjustment

The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment.

7.6 m

5 cm

1. Position the vehicle on a level surface with the headlight approxi-

mately 7.6 m from a wall.

2. Place the transmission in PARK.

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

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

NOTE: Include rider weight on the seat when measuring.

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

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

headlight beam should be 5 cm below the mark on the wall.

6. Tighten or loosen the lower headlight screws to adjust the beam

upward or downward or to the left or right.

MAINTENANCE

Lights

WARNING

Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently.

Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled.

Headlight/Position Light Lamp Replacement

When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Hold the plastic part of the lamp.

1. Place the transmission in PARK.

2. Open the front rack cover.

3. Remove the plug at the back of the

headlight.

4. Pull the harness plug to disconnect

it from the back of the headlight.

5. Position light: Rotate the socket to

remove it. Go to step 6. Headlamp: Reach under the bumper and remove the rubber cover from the back of the headlight. Turn the collar counterclockwise and carefully remove the collar and socket.

6. Remove the lamp. Apply dielectric

grease to the socket and install a new lamp.

7. Reverse all steps to reassemble the

headlight.

Position Light

Headlamp

Collar

Socket

MAINTENANCE

Lights

Taillight/Brakelight Lamp Replacement

1. From the rear of the brake-

light, 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.

Turn Signal Lamp Replacement

1. Place the transmission in

PAR K.

2. Remove the lens attachment

screw.

3. Rotate the lamp to remove it.

4. Install the new lamp.

5. Reinstall the lens.

Screw

Lamp

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 PARK.

2. Stop the engine.

3. Remove the drain screw on the

bottom of the recoil housing.

4. Allow the housing to drain com-

pletely.

5. Reinstall the drain screw.

NOTE: Do not open the crankcase drain

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

Housing

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 112 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

Plug Condition Torque Specification

New Spark Plug 12-15 N-m

Previously Installed Spark Plug 23-27 N-m

1. Remove the left side panel.

See page 75.

2. Remove the spark plug cap.

3. Use the spark plug wrench

to remove the spark plug. Turn the plug counterclockwise to remove it.

4. Inspect the electrodes for

wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation.

5. Reinstall the spark plug.

Torque to specification.

6. Reinstall the spark plug cap.

MAINTENANCE

Spark Plugs

Spark Plug Inspection

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

Normal Spark Plug

The normal insulator tip is tan or brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates overheating,

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 consumption, improper use of the choke or incorrect throttle body/carburetor adjustments.

caused by use of an improper spark plug or incorrect throttle body/ carburetor adjustments.

MAINTENANCE

Vehicle Immersion

CAUTION

If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following procedure.

1. Move the vehicle out of the

water.

2. Turn the fuel valve

off.

3. Remove the spark

plug.

OFF

4. Drain any water found in

the air box.

5. Loosen the carburetor drain screw

and drain the carburetor.

MAINTENANCE

Vehicle Immersion

6. Turn the ignition key past the

POSITION LIGHTS position to engage the starter. Engage the starter for only 2-3 seconds.

7. Tighten the carburetor drain screw.

8. Dry the spark plug.

Reinstall the plug or install a new plug.

9. Torque to specification.

10. Turn the fuel valve on.

11. Attempt to start the engine. If

necessary, repeat the drying procedure.

12. Have the vehicle serviced by

your dealer promptly, whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT, follow the procedure on page

88 for drying out the PVT.

MAINTENANCE

Spark Arrestor

Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor.

WARNING

Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors. Exhaust contains poisonous carbon monoxide gas. Never go under the vehicle while it's inclined.

Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the arrestor

clean-out plug from the bottom of the muffler.

4. Start the engine.

5. Quickly squeeze and

release the throttle lever several times to purge carbon from the system.

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

Wear protective gloves.

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

step 5.

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

the vehicle 30 cm higher than the front. Block the wheels.

9. Place the transmission in PARK. Repeat steps 5 to 7 until no more

particles are expelled.

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

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

plug.

Exhaust

Outlet

Clean-Out Plug

MAINTENANCE

PVT System

WARNING

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

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

• Always follow all recommended maintenance procedures. See 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 Drying

If water is ingested into the PVT system, dry it before operating the vehicle.

1. Move the vehicle out of the water.

2. Place the transmission in

PAR K.

PVT System

PVT Drying

3. Remove the PVT drain plug. Use a 17 mm wrench, a flat screwdriver, or the spark plug wrench.

4. Allow the water to drain completely. Reinstall the drain plug.

5. Start the engine. Place the transmission in PARK.

6. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.

NOTE: Do not hold the throttle wide

open for more than 10 seconds.

7. Allow the engine RPM to settle to idle speed, then shift the transmission to the lowest available range.

8. Test for belt slippage. If the belt slips, repeat the process.

9. Take the vehicle to your dealer for service as soon as possible.

MAINTENANCE

PVT Drain

Plug

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 PARK.

2. Open the front cover.

3. Disconnect the battery holddown strap.

4. On conventional batteries, remove the battery vent tube.

5. Disconnect the black (negative) battery cable first.

6. Disconnect the red (positive) battery cable last.

7. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle.

MAINTENANCE

Battery

Battery Installation

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed 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

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)

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 107 for the part numbers of Polaris products.

Lower

Mark

Upper

Mark

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 91.

2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. See page 92. Make sure the positive terminal is toward the front of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the 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.

MAINTENANCE

Battery

Battery Charging (Sealed Battery)

For a refresh charge, follow all instructions carefully.

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

2. 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

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.

instructions for recharging. When using a constant current charger, use the following guidelines for recharging.

WARNING

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.

High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.

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

2. Rinse with clean water frequently.

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

Washing Tips

• 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.

Polaris Hawkeye 300 2X4, Hawkeye 9920788, Scrambler 4X4 International User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual