Polaris Hawkeye 300 2X4 Owner's Manual
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Polaris Hawkeye 300 2X4 Owner's Manual

Polaris Hawkeye 300 2X4 Owner's Manual

Quadricycle
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Summary of Contents for Polaris Hawkeye 300 2X4

  • Page 3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • Quadricycles • RANGER utility vehicles •...
  • Page 4 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 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...

  • Page 5: Table Of Contents

    Adjustments ......103 Polaris Products..... . . 107 Troubleshooting .

  • Page 6: Know Your Vehicle

    Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys.

  • Page 7: Safety

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

  • Page 8: Safety Training

    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.

  • Page 9: Operator Safety

    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.
  • Page 10 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.
  • Page 11 SAFETY 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.
  • Page 12 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.
  • Page 13 SAFETY Operator Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 26. Always follow the procedures outlined in this manual for operating over obstacles.
  • Page 14 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.
  • Page 15 Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. For more information about Quadricycle safety, call Polaris at 1-800-342-3764.

  • Page 16: General Alert

    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.

  • Page 17: No Passenger" Warning

    SAFETY Safety Decals and Locations Rack Rack Warning Warning “No Passenger” Warning Tire Pressure/ Load Alert “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)

  • Page 18: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Eye Protection Long Helmet Sleeves Gloves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 19: Eye Protection

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.

  • Page 20: Driving Safely

    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.

  • Page 21: Turning The Vehicle

    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. Acti- vate 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...

  • Page 22: Driving On Slippery Surfaces

    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).

  • Page 23: Driving Over Obstacles

    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.

  • Page 24: Driving Uphill

    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.
  • Page 25 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.
  • Page 26 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.

  • Page 27: Driving Downhill

    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.
  • Page 28 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.
  • Page 29 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.

  • Page 30: Driving Through Water

    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.
  • Page 31 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. 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.

  • Page 32: Parking On An Incline

    SAFETY Driving Safely Parking on an Incline Avoid parking on an incline. If it's unavoidable, follow these precau- tions: 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.

  • Page 33: Driving In Reverse

    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.

  • Page 34: Hauling Cargo

    SAFETY Driving Safely 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 warning labels.

  • Page 35: Towing Loads

    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.

  • Page 36: Features And Controls

    FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Headlight Switch Engine Stop Switch Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page To gain additional power while operating in reverse, press the override switch before opening the throttle.

  • Page 37: Main Key Switch

    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.

  • Page 38: Turn Signal Switch

    FEATURES AND CONTROLS Switches All Wheel Drive Switch (4x4 Models) See page 44 for all wheel drive information. 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.

  • Page 39: Throttle Lever

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

  • Page 40: Foot Brake

    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.

  • Page 41: Parking Brake

    Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 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.

  • Page 42: Steering Lock

    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.

  • Page 43: Fuel Valve

    FEATURES AND CONTROLS Fuel Tank Cap Fuel Tank Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gaso- line 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.
  • Page 44 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 PARK.

  • Page 45: Recoil Starter

    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.
  • Page 46 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.

  • Page 47: Instrument Cluster

    Instrument Cluster The instrument cluster mea- sures distance in kilometers (or miles) as well as hours of oper- ation. It also includes a reverse speed limiter function that lim- its vehicle speed to approxi- mately 11-14 km/h. Refer to page 34 for additional informa- tion.

  • Page 48: Rider Information Center

    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.

  • Page 49: 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 between the rack and container could cause a spark.

  • Page 50: Break-In Period

    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 perfor- mance of your Quadricycle more than following the procedures for a proper break-in.

  • Page 51: Pre-Ride Checklist

    Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles, and...

  • Page 52: Starting The Engine

    OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating.

  • Page 53: Cold Weather Operation

    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.

  • Page 54: Emission Control Systems

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

  • Page 55: 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.

  • Page 56: Periodic Maintenance Chart

    E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
  • Page 57 (front gearcase) Transmission oil Engine breather filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride...
  • Page 58 MAINTENANCE Periodic Maintenance Chart Item Hours Calendar General lubrication Carburetor float bowl Throttle Cable/ ETC Switch Choke cable E Carburetor air intake ducts/flange Drive belt Engine oil change Oil filter change Oil tank vent hose (if equipped) Valve clearance Fuel system/filter Engine mounts Exhaust muffler/ pipe...
  • Page 59 Idle speed Toe adjustment Brakes Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 100 H 12 M 1000 (1600) Inspect;...

  • Page 60: Lubrication Guide

    Control Arm (front and rear) Bearing Carrier Transmission (upper pivot point) Front Prop Shaft Yoke Bearing Carrier Lube Polaris Premium 4 Synthetic 0W-50 DOT 4 Only Polaris AGL Synthetic Gearcase Lube Premium Demand Drive Hub Fluid Polaris Premium U-Joint Lube Method See page 59.

  • Page 61: Engine Oil

    0W-50 oil for this engine. PS-4 is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication per- formance 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.

  • Page 62: Oil Level

    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.

  • Page 63: Oil And Filter Change

    Oil and Filter Change 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.
  • Page 64 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.
  • Page 65 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. 21.

  • Page 66: Transmission Oil

    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.
  • Page 67 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.

  • Page 68: Oil Change

    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.
  • Page 69 Use the recommended fluid. Use of other fluids may result in improper operation of com- ponents. See page 107 for the part numbers of Polaris prod- ucts. Maintain the fluid level at the bottom of the fill hole threads. The fill plug is located on the right side of the gearcase.
  • Page 70 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.

  • Page 71: Fluid Change

    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.

  • Page 72: Brake Fluid

    If the fluid level is low add DOT 4 brake fluid only. See page 107 for the part numbers of Polaris products. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level.

  • Page 73: Hand Brake

    Brake Fluid Hand Brake The master cylinder is located on the left handle- bar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight.
  • Page 74 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...

  • Page 75: Brake Inspections

    Brakes The front and rear brakes are hydraulic disc brakes, activated by apply- ing either the hand brake or the foot brake. Both brake systems are self- adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition.

  • Page 76: Toe Alignment

    Rear measurement should be 2-3 mm more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. WARNING String Rear of Front Rim Front of...

  • Page 77: Side Panel Removal

    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.

  • Page 78: Tire Tread Depth

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loos- ened for service.
  • Page 79 Tires 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.
  • Page 80 MAINTENANCE Air Filter/Breather Filter Always clean and replace the air and breather filters at the intervals out- lined in the Periodic Maintenance Chart beginning on page 53. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.

  • Page 81: Headlight Beam Adjustment

    Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 7.6 m from a wall. 2.
  • Page 82 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. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.
  • Page 83 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.

  • Page 84: Recoil Housing

    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.

  • Page 85: Spark Plugs

    Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 112 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition New Spark Plug Previously Installed Spark Plug 1.

  • Page 86: Spark Plug Inspection

    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.

  • Page 87: Vehicle Immersion

    Vehicle Immersion 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.
  • Page 88 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.

  • Page 89: Spark Arrestor

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

  • Page 90: Pvt System

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

  • Page 91: Pvt Drying

    PVT System PVT Drying 3. Remove the PVT drain plug. Use a 17 mm wrench, a flat screw- driver, or the spark plug wrench. 4. Allow the water to drain com- pletely. Reinstall the drain plug. 5. Start the engine. Place the trans- mission in PARK.

  • Page 92: Conventional Battery

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

  • Page 93: Battery Removal

    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. Battery Removal 1.

  • Page 94: Battery Installation

    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 bat- teries do not have a vent tube). NOTE: The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent con- tact with electrolyte.

  • Page 95: Battery Storage

    NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
  • Page 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 91. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 97 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.

  • Page 98: Cleaning And Storage

    MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.

  • Page 99: Polishing The Vehicle

    • Cab and body panels • Labels and decals NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
  • Page 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. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 101: Storage Tips

    Make any necessary repairs and clean the vehicle as recommended. See page 96. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE:...
  • Page 102 7. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 103 2. Be sure the storage area is well ventilated. 3. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 104: Transporting The Vehicle

    Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Turn the fuel valve off. 4. Secure the fuel cap, oil cap and seat. 5. Remove the key to prevent loss during transporting.

  • Page 105: Adjustments

    The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Always adjust both sides equally. NOTE: Accessory springs are available through your Polaris dealer. Rear Adjuster Front Adjuster...
  • Page 106 Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Loosen the four handlebar bolts. 2. Adjust the handlebar to the desired height.

  • Page 107: Carburetor/Engine Idle Rpm Adjustment

    Carburetor Your Polaris Quadricycle is calibrated at the factory for optimal perfor- mance at altitudes ranging from zero to 1800 meters and temperatures of 4 degrees C. or higher. Above 1800 meters the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 300 meter increase in elevation.

  • Page 108: Throttle Cable Freeplay

    ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3.

  • Page 109: Polaris Products

    2872348 Chain Lube, Aerosol (473 ml) 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2872893 Engine Degreaser 2871956 Loctite 2871076 Polaris Battery Tender Engine Lubricant Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 110: Troubleshooting

    Dry out the PVT. See page 88. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer.
  • Page 111 Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Inspect, clean and/or replace spark plugs Immediately see your Polaris dealer Replace the filter Recharge the battery to 12.8 VDC See your dealer...
  • Page 112 Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Idle set too low Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...

  • Page 113: Engine Overheating

    Recharge the battery to 12.8 VDC Inspect and clean or replace See your dealer See your dealer See your dealer Clean engine exterior, see your Polaris dealer Solution Install the accessory oil cooler if the vehicle will be used for towing heavy loads, dragging ground surfaces or performing similar activities.

  • Page 114: Specifications

    78.5 x 68 250 w 9.2:1 Mikuni BST 34 42.5 147.5 0-4M 4HB42-5 DC CDI 10° +/- 2° @ 1500 RPM/30° +/- 2° @ 5000 RPM NGK CR8E / 0.8 mm Automatic PVT (Polaris Variable Transmission) Side Lever (H/N/R/P) 15.18:1...
  • Page 115 Hawkeye 2X4 International Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brake, Hand Brake, Foot Brake, Parking Headlight Taillights Brake Light Battery Electric Start Neutral Indicator Reverse Indicator Speedometer/Odometer/ Tripmeter/Hourmeter Fuel Gauge Tool Kit DC Plug-In (rear) Windshield Jetting Chart ALTITUDE Meters...
  • Page 116 78.5 x 68 250 w 9.2:1 Mikuni BST 34 42.5 147.5 0-4M 4HB42-5 DC CDI 10° +/- 2° @ 1500 RPM/30° +/- 2° @ 5000 RPM NGK CR8E / 0.8 mm Automatic PVT (Polaris Variable Transmission) Side Lever (H/N/R/P) 3.6:1 15.18:1...

  • Page 117: Jetting Chart

    Hawkeye 4X4 International Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brake, Hand Brake, Foot Brake, Parking Headlight Taillights Brake Light Battery Speedometer/Odometer/ Tripmeter/Hourmeter Fuel Gauge Electric Start Neutral Indicator Reverse Indicator Tool Kit DC Plug-In (rear) Windshield Jetting Chart ALTITUDE Meters...

  • Page 118: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE.
  • Page 119 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any Quadricycle...
  • Page 120 HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris Quadricycles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

  • Page 121: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 122 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 123: Index

    Accessories ....101 Age Restrictions ....6 Air Filter .
  • Page 124 Periodic Maintenance Chart ..53-57 Polaris Product List ... . 107 Polishing the Vehicle... . . 97 Position Light Lamp .

  • Page 125: Index

    Taillight..... . . 81 Throttle Cable Freeplay ..106 Throttle Lever ....37 Tire Tread Depth.

This manual is also suitable for:

Hawkeye 9920788Scrambler 4x4 internationalHawkeye 2x4 2007Hawkeye 4x4 2007

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