Polaris 2009 Hawkeye 2X4 Owner'S Manual Download Page 70

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MAINTENANCE

Front Gearcase (Demand Drive) Fluid

(if equipped)

Fluid Check

1. Position the vehicle on a level

surface.

2. Place the transmission in gear.
3. Lock the parking brake.

4. Remove the fill plug. Use

an 8 mm Allen wrench.

5. Check the oil level.
6. Add the recommended oil

as needed to bring the level

to the bottom of the fill

hole threads.

7. Reinstall the fill plug.

Torque to specification.

See page 67.

Summary of Contents for 2009 Hawkeye 2X4

Page 1: ......

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Page 3: ...rcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service...

Page 4: ...and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication...

Page 5: ...Your Vehicle 5 Safety 6 Features and Controls 20 Operation 32 Emission Control Systems 53 Maintenance 54 Adjustments 101 Polaris Products 105 Troubleshooting 106 Specifications 110 Warranty 114 Maint...

Page 6: ...4...

Page 7: ...ur 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...

Page 8: ...t 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 s...

Page 9: ...ations The warranty on your Polaris vehicle may be terminated if any equip ment has been added or if any modifications have been made that increase speed or power NOTE The addition of certain accessor...

Page 10: ...at www polarisindustries com Never permit others to operate this vehicle unless they have read and under stand this manual and all product labels and have completed a certified safety training course...

Page 11: ...or face shield gloves boots long sleeves and long pants Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Travel and turn at speeds appropriate f...

Page 12: ...ting condition Follow the inspection and maintenance procedures outlined in this manual See page 35 Keep both hands on the handlebars Keep both feet on the footrests Always travel slowly when operatin...

Page 13: ...low the procedures outlined in this man ual for driving on hills See page 43 Never operate on hills too steep for this vehicle or for your abili ties Practice on smaller hills before attempting larger...

Page 14: ...s follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 42 Always follow the procedures outlined in this...

Page 15: ...s avoid operating this vehicle on paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on a public street road or highway including a dirt or gravel road Al...

Page 16: ...decal General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH D...

Page 17: ...ll REVERSE operation can be dan gerous even at low speeds Steer ing becomes difficult To prevent loss of control avoid sudden brak ing or sharp turns 7175511 Tire Pressure Load Warning WARNING Imprope...

Page 18: ...oss of control resulting in SEVERE INJURY or DEATH 7175378 Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this A...

Page 19: ...ax Rack Loads Front 70 lbs 32 kg Rear 100 lbs 46 kg Reverse Override Warning 4X4 Models WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not a...

Page 20: ...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 distin...

Page 21: ...rsonal 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...

Page 22: ...eel Drive in reverse if the AWD switch is on This switch is also used to toggle through the modes of the rider information center See page 30 WARNING Activating the override switch while the throttle...

Page 23: ...ght switch to turn the lights on and off and to change the lights from high beam to low beam NOTE The lights won t work unless the key is in the ON position and the engine stop switch is in the RUN po...

Page 24: ...throttle controls could cause an accident and lead to severe injury or death Never start or operate this vehicle with a sticking or improperly operating throttle Always contact your dealer for service...

Page 25: ...and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected be...

Page 26: ...ant Safeguards The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of this vehicle if leav ing it p...

Page 27: ...the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Check the brake fluid level frequently for the auxiliary brake system See page 71 WARNING Aggressively applyin...

Page 28: ...e number of 87 R M 2 octane Do not use E 85 fuel Fuel Valve The fuel valve is located on the bottom of the fuel tank Access the fuel valve through the right front wheel well or from the front of the v...

Page 29: ...Neutral R Reverse Whenever this vehicle is left unattended always place the transmission in gear and lock the parking brake CAUTION Shifting gears with the engine speed above idle or while the vehicle...

Page 30: ...st until the engine rolls past the stroke then stop pulling immediately 3 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 4 Repe...

Page 31: ...ere is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not e...

Page 32: ...ange 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 b...

Page 33: ...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 vehi...

Page 34: ...not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an e...

Page 35: ...icient performance and longer life for these components Install the accessory oil cooler when the following conditions exist The vehicle will be used for towing heavy loads The vehicle will be used fo...

Page 36: ...not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 35 6 Pull only light loads 7 During the break in...

Page 37: ...ressure 75 Wheels fasteners Inspect ensure fastener tightness 75 77 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 26 61 Coolant level if applicable Ensure prope...

Page 38: ...pull the choke knob out until it stops NOTE The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradu...

Page 39: ...ne does not start and all conditions are favorable change the spark plug and try again 10 If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engin...

Page 40: ...o maintain stable driving conditions Do not obstruct the headlight beam with cargo Towing Loads Always attach a towed load to the hitch point If towing a load reduce rear rack cargo weight by the amou...

Page 41: ...e operating conditions which could result in loss of control of the vehi cle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten...

Page 42: ...nds on the handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly dep...

Page 43: ...n of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This tech nique alters the balance of trac tion between the rear wheels allowing the...

Page 44: ...rning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow...

Page 45: ...opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle WARNING Braking and handling are greatly affected when operating in hilly terrain Imp...

Page 46: ...your feet on the footrests 4 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheel downhill if pos sible or dismount on the uphill s...

Page 47: ...ore operating your vehicle learn how to use the auxiliary brake for emergency situations if single lever brakes become inoperable WARNING Excessive speed when traveling downhill can cause loss of cont...

Page 48: ...46 OPERATION Driving Safely Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 8 ft 2 4 m...

Page 49: ...ll of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the...

Page 50: ...f the footrests Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly av...

Page 51: ...fully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossibl...

Page 52: ...he terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hid den obs...

Page 53: ...y increased Do not operate at wide open throttle WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles...

Page 54: ...cline 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...

Page 55: ...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 on...

Page 56: ...ce and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of appr...

Page 57: ...d 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...

Page 58: ...s fasteners Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air filter pre filter Daily Inspect clean often replace as needed X Air box sediment tube Daily Drain deposits when visibl...

Page 59: ...ect adjust replace as needed X Engine oil change 100 H 6 M 1000 1600 Perform a break in oil change at 20 hours X Oil filter change 100 H 6 M 1000 1600 Replace with oil change X Oil tank vent hose if e...

Page 60: ...hever comes first Remarks Hours Calendar Miles Km Q Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as neede...

Page 61: ...luid DOT 4 Only See page 70 Transmission Oil Polaris AGL Synthetic Gearcase Lube See page 64 Front Demand Drive Unit Front Gearcase if equipped Premium Demand Drive Hub Fluid See page 67 Front Prop Sh...

Page 62: ...d to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation Oil Specifications CAUTION Mixing brands or...

Page 63: ...ssion in neutral 3 Lock the parking brake 4 Start the engine Allow it to idle for 30 seconds Stop the engine 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely 7...

Page 64: ...4 Start the engine Allow it to idle for two to three minutes Stop the engine 5 Clean the area around the drain plug 6 Place a drain pan under the vehicle 7 Remove the drain plug Use a 6 mm Allen wrenc...

Page 65: ...l the new oil filter After the filter contacts the engine surface turn it 1 2 turn by hand 15 Remove the dipstick 16 Add the recommended oil See page 60 17 Reinstall the dipstick 18 Start the engine A...

Page 66: ...The fill plug is located on the left side of the vehicle under the rear fender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations Gearcase Lubricant Capa...

Page 67: ...le 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...

Page 68: ...wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use a 15 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 64 fo...

Page 69: ...of compo nents See page 105 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the gearcase The drai...

Page 70: ...a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use an 8 mm Allen wrench 5 Check the oil level 6 Add the recommended oil as needed to bring the level t...

Page 71: ...e 4 Remove the fill plug Use an 8 mm Allen wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use an 11 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain...

Page 72: ...sure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up...

Page 73: ...ht 2 View the fluid level through the indicator win dow 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 t...

Page 74: ...mmended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 70 2 Check the b...

Page 75: ...NOTE If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 2 3 mm...

Page 76: ...is 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 t...

Page 77: ...performed by your authorized Polaris dealer WARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and...

Page 78: ...hicle 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 th...

Page 79: ...que Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service WARNING Improperly installed wheels can adversely affect tire wear and vehicle han dling which c...

Page 80: ...water then rinse and let dry 9 Remove the breather filter 10 Wash the breather filter in soapy water then rinse and let dry 11 Reinstall the breather filter 12 Reinstall the sleeve over the air filter...

Page 81: ...Lock the parking brake 4 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 5 Start...

Page 82: ...y 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 From the rear of the brake light remove the two screws holding the lens cover in place Remove t...

Page 83: ...g is completely dry before reinstalling the drain plug 1 Place the transmission in gear 2 Lock the parking brake 3 Stop the engine 4 Remove the drain screw on the bottom of the recoil housing 5 Reinst...

Page 84: ...he spark plug for correct color See page 83 1 Remove the left side panel 2 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 3 Using the special wrench provided in the tool pouch rotat...

Page 85: ...rodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service NOTE The tip should not be flaky and white A white insulator tip indicates overheating caus...

Page 86: ...using the electric start 7 Dry the spark plug Reinstall the plug or install a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat...

Page 87: ...cm higher than the front Block the wheels 10 Place the transmission in neutral Lock the parking brake Repeat steps 6 to 8 until no more particles are expelled 11 Stop the engine Allow the arrestor to...

Page 88: ...ional 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 p...

Page 89: ...ow the water to drain com pletely Reinstall the drain plug 4 Start the engine Place the trans mission in neutral 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt a...

Page 90: ...th clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING Battery electrolyte is poi...

Page 91: ...ttery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte WARNING Improperly connecting or disconnecting battery cables can result in an explo sion a...

Page 92: ...ions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte 4 On conventional batteries coat the terminals with dielectric grease or petroleum...

Page 93: ...ender 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 vol...

Page 94: ...he 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 s...

Page 95: ...tandard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 mont...

Page 96: ...h 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...

Page 97: ...aler 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 Polishing the...

Page 98: ...t Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodic...

Page 99: ...exhaust sys tems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil a...

Page 100: ...of the machine so the engine is level or tilted slightly rearward 3 Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of engine oil into the cylinder 4 Reinstall the spark plug...

Page 101: ...the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven tilation to prevent cond...

Page 102: ...e 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 Always tie the frame of the vehi...

Page 103: ...tments 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 Ac...

Page 104: ...right 3 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear bolts WARNING Improper adjustment of the handlebars or incorr...

Page 105: ...m your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause...

Page 106: ...xpose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever NOTE While adjust...

Page 107: ...2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season...

Page 108: ...ge only if equipped Utility use plowing Use low range only if equipped Stuck in mud or snow Shift the transmission to low range if equipped Care fully use fast aggressive throttle application to engag...

Page 109: ...l valve on Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop swit...

Page 110: ...tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended...

Page 111: ...cs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filt...

Page 112: ...74 in 188 cm Overall Width 42 in 107 cm Overall Height 45 5 in 116 cm Wheelbase 46 in 117 cm Ground Clearance 8 in 20 cm Minimum Turning Radius 62 5 in 159 cm unloaded Engine Model Number Type ES300P...

Page 113: ...H DC Plug In rear Accessory Windshield Accessory Speedometer Odometer Tripmeter Hourmeter Standard Fuel Gauge Standard Tool Kit Standard ALTITUDE Meters Feet AMBIENT TEMPERATURE Below 40 F Below 5 C 4...

Page 114: ...213 lbs 550 kg Overall Length 74 in 188 cm Overall Width 42 in 107 cm Overall Height 45 5 in 116 cm Wheelbase 46 in 117 cm Ground Clearance 8 in 20 cm Minimum Turning Radius 62 5 in 159 cm unloaded En...

Page 115: ...hts 12V 8 26W Brake Light 12V 26 9W Battery 12V 14AH DC Plug In rear Accessory Windshield Accessory Speedometer Odometer Tripmeter Hourmeter Standard Fuel Gauge Standard Tool Kit Standard ALTITUDE Met...

Page 116: ...aris 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 ORDE...

Page 117: ...ble with the Quadricycle The exclusive remedy for breach of this war ranty shall be at Polaris exclusive option repair or replacement of any defective materi als or components or products THE REMEDIES...

Page 118: ...ONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty...

Page 119: ...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 OR HOURS TECH...

Page 120: ...118 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 121: ...119 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 122: ...ing Chart 2X4 111 Clutching Chart 4X4 113 Cold Weather Operation 37 Corrosion Removal Chrome 96 D Demand Drive Fluid 67 69 Drive Belt Wear Burn 106 Drivetrain Break In 34 Driving Downhill 45 Driving i...

Page 123: ...ride Switch 20 P Parking Brake 24 Parking on an Incline 52 Periodic Maintenance Chart 54 58 Polaris Product List 105 Polishing the Vehicle 95 Pre Ride Checklist 35 PVT Break In 34 PVT Drying 87 PVT Sy...

Page 124: ...ghtening 75 Tread Depth 75 Wheel Installation 77 Wheel Nut Torque 77 Wheel Removal 76 Toe Alignment 73 Towing Loads 38 Training Safety 7 Transmission Oil 64 66 Transporting the Vehicle 100 Turning Aro...

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Polaris 2009 Hawkeye 2X4, Owner'S Manual

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