Polaris 922362 - Manual

5 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazar...

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

7 INTRODUCTION 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 o...

8 SAFETY Operator Safety 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 ope...

13 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 tow...

14 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided...

15 SAFETY Safety Labels and Locations Discretionary Warning WARNING• Never operate this ATV on HILLS steeper than 25 degrees 25 ° . To prevent overturn on hilly ter- rain, use throttle and brakes grad-ually, and shift weight uphill. • REVERSE operation can be dan- gerous even at low speeds. Steer- i...

16 SAFETY Safety Labels and Locations “No Passenger” Warning WARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Age 16 Warning WARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or death.N...

17 SAFETY Safety Labels and Locations Clutch Cover Warning WARNINGNO 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 RP...

18 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Always wear a helmet that meets or exceeds established safety stan- dards.Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.Approved helmets in Europe, Asia and...

19 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing mark...

20 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch.The override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on. This swit...

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

22 FEATURES AND CONTROLS Throttle Lever 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. Failure to check or maintain proper operation of the throttle system can result in an...

23 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 sque...

24 FEATURES AND CONTROLS Parking Brake Operating this vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1. Place the transmission in gear. 2. Squeeze ...

25 FEATURES AND CONTROLS Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could res...

26 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 36 for correct choke and throttle settings during start- ing. Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a ...

27 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearN: NeutralR: ReverseWhenever this vehicle is left unattended, always place the transmission in gear and lock the parking brake. Shifting gears with th...

29 FEATURES AND CONTROLS All Wheel Drive (AWD) System (4X4 Models) The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the vehicle is in two-wheel drive at all times. When the switch is on AWD, the vehicle is in all wheel drive and the AWD indicator light in the in...

30 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 ve...

31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg- ments will light up for 3 seconds at start-up.1. Gear Indicator - This indicator displays gear shifter position. N = Neutral (Green) R = Reverse (Amber) 2....

32 OPERATION Fuel Safety 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 bet...

34 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26.2. Check the oil level on the dipstick. See page 61. Add oil if neces- sary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an open area that allows roo...

35 OPERATION Pre-Ride Checklist 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 72 Brake fluid Ensu...

36 OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface.2. Place the transmission in neutral.3. Lock the parking bra...

37 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 attempt...

38 OPERATION Driving Procedures 1. Wear protective riding gear. See page 18.2. Perform the pre-ride inspection. See page 35.3. Sit upright with both feet on the footrests and both hands on the handlebars. 4. Start the engine and allow it to warm up. 5. Shift the transmission into gear.6. Check your ...

39 OPERATION 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...

40 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather, follow these precautions:1. Do not operate on exces- sively rough, slippery or loose terrain. 2. Slow down when enter- ing slippery areas. 3. Engage AWD (i...

41 OPERATION Driving Uphill Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Whenever traveling uphill, follow these precautions:1. Drive straight uphill.2. Avoid steep hills...

42 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down.2. Avo...

43 OPERATION Driving Downhill When driving downhill, follow these precautions:1. Before operating your vehicle, learn how to use the auxiliary brake for emergency situations (if single-lever brakes become inoperable). 2. Always check the terrain carefully before descending a hill.3. Shift your weigh...

45 OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill.2. Leave the transmission in forward and shut off the engine.3. Dismount on the uphill side of the vehicle, or on the left if the vehi- cle is pointing straight uphill. 4. Staying uphil...

46 OPERATION 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 gradu...

47 OPERATION Driving Through Water If it’s unavoidable to enter water deeper than the footrest level: • Proceed slowly. Avoid rocks and obstacles.• Balance your weight carefully. Avoid sudden movements.• Maintain a steady rate of speed. Do not make sudden turns or stops. Do not make sudden throttle ...

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

49 OPERATION 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 sudde...

50 OPERATION Hauling Cargo 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 warni...

51 OPERATION 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 specifi- cations section of the owner's manual and on the safety ...

52 OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Place the transmission in gear.3. Lock the parking brake.4. Always block the rear wheels on the downhill side.5. Turn the fuel valve off.

53 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 operatio...

54 MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently.Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals t...

55 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a „ could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these ...

59 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic 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 Synthetic ...

60 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 u...

61 MAINTENANCE 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. Rem...

62 MAINTENANCE Oil and Filter Change Hot oil may result in serious burns. Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Always change the oil filter whenever changing oil.1. Position the vehicl...

64 MAINTENANCE 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...

65 MAINTENANCE 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 specific...

66 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 ...

67 MAINTENANCE Front Gearcase (Demand Drive) Fluid (if equipped) Always check and change the demand drive fluid at the inter- vals 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...

68 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 bri...

69 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....

70 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 m...

71 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Main- tain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder. Do not over- fill.1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View the fluid l...

72 MAINTENANCE 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 syst...

73 MAINTENANCE Toe Alignment Do not attempt to adjust tie rod alignment. All tie rod 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 le...

74 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Spring Adjustments The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Always adjust both sides equally. Tip: Accessory sp...

75 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal inju...

76 MAINTENANCE Carburetor This vehicle is calibrated at the factory for optimal performance at alti- tudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine los...

77 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar.1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut.4. Rotate the...

78 MAINTENANCE Steering Assembly The steering assembly of this vehicle should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat.2. Grasp the top of the side pane...

79 MAINTENANCE Tires 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 label on your ve...

80 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. Rem...

81 MAINTENANCE Tires Wheel Installation 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 ...

82 MAINTENANCE Air Filter/Breather Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear.3. Lock the parking brake.4. Remove the seat. 5. Release the air box cover clips, and remove the air box cover. 6. Remove the air filter.7. Remove the sleeve from the filter. 8. Wa...

83 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in n...

84 MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlamp Replacement When s...

85 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the housing before storing the vehicle. Make sure the hous- ing is completely dry before reinstalling the drain plug.1. Place the transmission in gear.2. Lock the parking brake.3. Sto...

86 MAINTENANCE Spark Plugs Spark Plug Recommendations Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 110 for the recom- mended spark plug type and gap for your vehicle. Torque sp...

87 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 Norma...

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

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

90 MAINTENANCE PVT System 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 c...

91 MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating.1. Move the vehicle out of the water. 2. Remove the PVT drain plug. Use a 17 mm wrench, a flat screwdriver, or the spa...

92 MAINTENANCE Battery 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. Bat...

93 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear. 2. Lock the parking brake. 3. Open the front cover.4. Disconnect the battery hold- down strap. 5. On conventional batteries, remove the battery vent tube. 6. Disconnect the black (nega- tive) battery cable first. 7. Disconnect...

94 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 96 before installing the battery.1. Ensure that the battery ...

95 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 ...

96 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 93. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as neede...

97 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 mos. ...

98 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, usin...

99 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 labels. Avoid directing the water stream at the follow- ing items: • Wheel bearings• Tr...

100 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more suscep...

101 MAINTENANCE Cleaning and Storage Storage Tips 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 recomme...

102 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 lo...

103 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 54. Battery Storage See pages 95-96 for storage and charging procedures. Storage Area/Covers 1. Set the...

104 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in gear.3. Lock the parking brake.4. Turn the fuel valve off.5. Secure the fuel cap, oil cap and seat.6. Remove the key to prevent loss during transporting.7. A...

105 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcas...

106 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range (if equipped). Starting out going up a steep incline Use low range (if equipped) or turn around using the K- turn (see page 44). Driving at low RPM or ground speed (3-7 ...

107 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Blown fuse Replace fuse Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connec...

108 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too...

109 TROUBLESHOOTING Engine Stops or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Overuse of choke Insp...

110 SPECIFICATIONS * Based on EU Directive 76/432/EC HAWKEYE 2X4 Gross Vehicle Weight 930 lbs. (422 kg) Dry Weight 525 lbs. (238 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) Transmission Oil 15.2 oz. (450 ml) Front Rack Capacity 70 lbs. (32 kg) Rear Rack Capacity 100 lbs. (45...

111 SPECIFICATIONS Jetting Chart Clutching Chart HAWKEYE 2X4 Tires/Pressure, Front 22x7-12 / 5 psi (34.5 KPa) Tires/Pressure, Rear 22x10-12 / 5 psi (34.5 KPa) Front Suspension MacPherson strut with 7" (18 cm) travel Rear Suspension Progressive rate with 8" (20 cm) travel Shock Adjustment CAM...

114 DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. PRODUCT IDENTIFIC...

115 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris vehicle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective par...

116 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination, for which they were not designed or not intended, including but not limited to the following items: Warranty applies to the prod...

118 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser-vices perfor med. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

121 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 103 Age Restrictions . . . . . . . . . . . . . . . . . 6 Air Filter . . . . . . . . . . . . . . . . . . . . . . 82 All Wheel Drive Switch . . . . . . . . . . 21 All Wheel Drive System . . . . . . . . . . 29 AWD Switch . . . . . . . . . . ...