Polaris Hawkeye 2X4 2007 Owner'S Manual Download

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Summary of Contents for Hawkeye 2X4 2007

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Page 3: ...hed to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 4: ...r safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 5: ...lity 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 are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expres...

Page 6: ...w Your Vehicle 5 Safety 6 Features and Controls 34 Operation 46 Emission Control Systems 67 Maintenance 68 Adjustments 115 Polaris Products 119 Troubleshooting 120 Specifications 124 Warranty 128 Maintenance Log 134 Index 136 ...

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Page 8: ... in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN _______________________________________________...

Page 9: ...ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and...

Page 10: ...re Pressure Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 930 LBS 422 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unse...

Page 11: ...ause a loss of control resulting in SEVERE INJURY or DEATH Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 No Passenger Warning Clutch Cover Warning Age 16 Warning Rack Warning Rack Warning ...

Page 12: ...ax Rack Loads Front 70 lbs 32 kg Rear 100 lbs 46 kg Reverse Override Warning 4X4 Models WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in AWD See Owner s Manual Override Switch 2X4 Models Reverse speed is limited Reverse override is controlled by the override switch S...

Page 13: ...eeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the l...

Page 14: ...ersonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a je...

Page 15: ...n severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle han dles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operati...

Page 16: ...ing procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operati...

Page 17: ...rt symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note ...

Page 18: ...te an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an ATV Never operate at excessive speeds Travel at speeds appropriate for the terr...

Page 19: ...f a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight uphill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Drive straight downhill Always follow proper procedures for crossing the side of a hill Av...

Page 20: ...n Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp an...

Page 21: ... make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of c...

Page 22: ...e and the operating techniques described in the Owner s Manual For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation oper ates an ATV Even though a ...

Page 23: ... is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operat ing on paved surfaces may adversely affect the handling of the ATV and could result in loss of control acciden...

Page 24: ... POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOI...

Page 25: ... operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE...

Page 26: ...er stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures...

Page 27: ...ld contact the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn...

Page 28: ...ate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for...

Page 29: ...se loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 degrees Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill...

Page 30: ...hich would cause the vehicle to lean sharply to one side Travel straight down the hill when possible WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level groun...

Page 31: ...ill Apply the brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the AT...

Page 32: ...les such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper pro cedures as outlined in the owner s manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly an...

Page 33: ... your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN Th...

Page 34: ...bed in the owner s manual and on safety decals WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehi...

Page 35: ...ity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater dis tance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operat...

Page 36: ...isabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling...

Page 37: ...All Wheel Drive in reverse if the AWD switch is on This switch is also used to toggle through the modes of the rider information center See page 44 WARNING Activating the override switch while the throttle is open can cause loss of con trol resulting in severe injury or death Do not activate the override switch while the throttle is open Mode Reverse Override Switch Main Key Switch Engine Stop Swi...

Page 38: ...eadlight 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 position All Wheel Drive Switch 4x4 Models See page 43 for all wheel drive information WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious i...

Page 39: ...hrottle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free moveme...

Page 40: ...ravel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the...

Page 41: ...portant 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 the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill posi tion Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling WARNING Operat...

Page 42: ... 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 85 WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxilia...

Page 43: ...ne number of 87 R M 2 octane Do not use E 85 fuel Fuel Valve The fuel valve is located on the bottom of the fuel tank Access the fuel valve through the right front wheel well or from the front of the vehicle ON For normal operation OFF For vehicle storage and when transporting Refuel when the instrument gauge indicates a low fuel level Fuel Filter The in line fuel filter should be replaced by your...

Page 44: ... N Neutral R Reverse Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Gear Selector ...

Page 45: ...ust 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 Repeat all steps until the engine starts 5 Make sure the handle is fully seated on the housing CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not exte...

Page 46: ... is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not dise...

Page 47: ...hange modes press and release the mode button see page 31 as often as needed to reach the odometer mode 2 In the odometer mode press and hold the mode button until the let ters flash then release the button 3 Press and release the button one more time When the display stops flashing the mode has been set CAUTION High water pressure may damage ATV components Wash the ATV by hand or with a garden ho...

Page 48: ... NOTE If using the mode button to program the rider information center or to toggle through the options the transmission cannot be in reverse Odometer The odometer records the distance traveled by the ATV Trip Meter The trip meter records the distance traveled by the ATV on each trip if it s reset before each trip To reset the trip meter toggle to the trip meter mode Press and hold the mode button...

Page 49: ... not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the vehicle is stored or parked WARNING The engine exhaus...

Page 50: ...cient performance and longer life for these components Install the accessory oil cooler when the following conditions exist The vehicle will be used for towing heavy loads The vehicle will be used for dragging ground surfaces or performing similar activities The vehicle is normally operated when the air temperature is above 100 F 38 C CAUTION Excessive heat build up during the first three hours of...

Page 51: ... not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 49 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutche...

Page 52: ...pressure 89 Wheels fasteners Inspect ensure fastener tightness 89 91 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 40 75 Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 36 118 Indicator lights switches Ensure operation 34 Engine stop switch Ensure proper operation 35 Air filter pr...

Page 53: ... 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 gradually depending on how much choke is needed for starting Be sure the choke is off during opera tion as excess fuel wash ing into the engine oil will increase wear on engine components 7 Move the engin...

Page 54: ...engine 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 engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in Cold Weather Operation If the ATV is used year round check the oil level frequently A...

Page 55: ...ght to maintain stable driving conditions Do not obstruct the headlight beam with cargo Towing Loads Always attach a towed load to the hitch point If towing a load reduce rear rack cargo weight by the amount of tongue weight The combina tion of rear rack cargo weight and tongue weight must not exceed the rear rack capacity CAUTION Using an improper hitch or exceeding the maximum tongue weight capa...

Page 56: ...le 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 the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying...

Page 57: ...ands on the handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress the throttle with your right thumb and begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 58: ... 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 turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning at sharp a...

Page 59: ...urning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire...

Page 60: ...e opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in seri ous injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper oper...

Page 61: ... your feet on the footrests 4 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheel downhill if pos sible or dismount on the uphill side immediately WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when poss...

Page 62: ...Before operating your ATV 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 control and seri ous injury or death Slow down Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control and serious injury or death Apply the brakes gradually ...

Page 63: ...60 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 64: ...ill 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 hill or slightly downward 6 Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill 7 Start the engine with the transmission still in forward 8 Release the parking...

Page 65: ... the footrests Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal Maximum Depth ...

Page 66: ...efully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 98 Have the vehicle serviced by your dealer at the first opportunity CAUTION Major engine damage can result if the vehic...

Page 67: ...the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hid den obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain ...

Page 68: ... 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 or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and...

Page 69: ...ncline 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 ...

Page 70: ...ine at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ign...

Page 71: ...ice 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 approximately 10 miles per hour 16 km h Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style ...

Page 72: ...ed service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Q Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked with a Q could result in com ponent failure and lead to serious injury or death Have an authorized Polaris dealer perform these services ...

Page 73: ...ls 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 visible Headlamp tail lamp Daily Check operation apply dielectric grease if replacing X E Air filter main element Weekly Inspect replace as needed Recoil housing if applicable Weekly Drain water as needed ...

Page 74: ...pect 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 equipped 100 H 6 M 1000 1600 Inspect routing condition Q E Valve clearance 100 H 12 M 1000 1600 Inspect adjust Q E Fuel system filter 100 H 12 M 1000 1600 Check for leaks at tank cap lines fuel valve ...

Page 75: ...chever 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 needed Q Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out Idle speed Adjust as needed Q Toe adjustment Inspect periodically adjust when parts are repla...

Page 76: ...ake Fluid DOT 4 Only See page 84 Transmission Oil Polaris AGL Synthetic Gearcase Lube See page 78 Front Demand Drive Unit Front Gearcase Premium Demand Drive Hub Fluid See page 81 Front Prop Shaft Yoke Polaris Premium U Joint Lube Grease fittings 3 pumps maxi mum every 500 miles 800 km before long periods of storage or after pressure washing or submerging Control Arm front and rear Bearing Carrier...

Page 77: ...ce 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 Oil Specifications CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Lubricant Capacity Drain Plug Torque Performa...

Page 78: ...sion in neutral 3 Lock the parking brake 4 Start the engine Allow it to idle for 30 seconds Stop the engine 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely 7 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 8 Reinstall the dipstick Dipstick Safe Add Oil Safe Range ...

Page 79: ... 4 Start the engine Allow it to idle for two to three minutes Stop the engine 5 Clean the area around the drain plug 6 Place a drain pan under the vehicle 7 Remove the drain plug Use a 6 mm Allen wrench 8 Drain the oil 9 Reinstall the drain plug with a new sealing washer NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 10 Torque to spec...

Page 80: ...ll 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 74 17 Reinstall the dipstick 18 Start the engine Allow it to idle for two minutes 19 Stop the engine 20 Check for oil leaks 21 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 22 ...

Page 81: ...ts The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Transmission 2x4 Premium AGL Synthetic Gearcase Lubricant 15 2 oz 450 ml 15 ft lbs 20 Nm 15 ft lbs 20 Nm Transmission 4x4 Premium AGL Synthetic Gearcase Lubrican...

Page 82: ...cle on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use a 15 mm wrench 5 Check the oil level 6 Add oil as needed Do not overfill 7 Reinstall the fill plug Torque to specification See page 78 for recom mendations ...

Page 83: ... 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 78 for recommendations 9 Add the recommended oil 10 Reinstall the fill plug Torque to specification See page 78 for recommenda tions 11 Check for leaks 12 Dispose of used oil properly ...

Page 84: ... of compo nents See page 119 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the gearcase The drain plug is located on the bot tom right side of the gearcase Demand Drive Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Demand Drive Unit Premium Demand Drive Hu...

Page 85: ...el 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 81 ...

Page 86: ...emove the fill plug Use an 8 mm Allen wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use an 11 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 81 9 Add the recommended fluid 10 Reinstall the fill plug Torque to specification 11 Check for leaks 12 Dispose of used oil properly ...

Page 87: ...nsure 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 which could result in serious injury or death Maintain brake fluid at the recom mended level Do not overfill WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic mea...

Page 88: ...aight 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 the recommended fluid as needed Do not overfill Foot Brake The brake fluid reservoir is located on the right side of the ATV Maintain the fluid level between the minimum and maximum marks Do not ove...

Page 89: ...ommended 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 84 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the fric tion material is worn to 03 8...

Page 90: ...ear tires on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim Rear measurement should be 1 16 to 1 8 2 3 mm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service WARNING Severe injury or death can result from improper toe alignmen...

Page 91: ...s dealer for service before operating the vehicle Side Panel Removal 1 Remove the seat 2 Grasp the top of the side panel and pull it outward to remove it Footwell Removal 1 Remove the two screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell Screws Rivets Rivets ...

Page 92: ...st be performed by your authorized Polaris dealer WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual Always use original equipment size and type ...

Page 93: ...ehicle on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Loosen the wheel nuts slightly 5 Place a suitable stand under the footrest frame to raise the wheel slightly off the ground 6 Remove the wheel nuts 7 Remove the wheel ...

Page 94: ...rque 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 can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer Nut Type Nut Torque Lug...

Page 95: ... 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 Replace the filter if needed 13 Reinstall the air filter into the air box 14 Reinstall the air box cover and the seat CAUTION Operation of your vehicle without a breather filter can cause engine dam...

Page 96: ... Lock the parking brake 4 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 5 Start the engine Turn the headlight switch to high beam 6 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall 7 Loosen the...

Page 97: ...ly 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 the lens cover 2 Remove the lamp and replace it with a new lamp 3 Test the light for proper operation 4 Reinstall the lens cover WARNING Poor lighting while driving can result in severe injury or deat...

Page 98: ...ng is completely dry before reinstalling the drain plug 1 Place the transmission in gear 2 Lock the parking brake 3 Stop the engine 4 Remove the drain screw on the bottom of the recoil housing 5 Reinstall the drain screw NOTE Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crank case drain is opened ...

Page 99: ...the spark plug for correct color See page 97 1 Remove the left side panel 2 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 3 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Plug Condition Torque Specifica...

Page 100: ...trodes 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 caused by use of an improper spark plug or incorrect carburetion adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer ...

Page 101: ...s using the electric start 7 Dry the spark plug Reinstall the plug or install a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying proce dure 11 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not 12 If water has been ingested into the PVT follow the procedure on page...

Page 102: ... cm higher than the front Block the wheels 10 Place the transmission in neutral Lock the parking brake Repeat steps 6 to 8 until no more particles are expelled 11 Stop the engine Allow the arrestor to cool 12 Reinstall the arrestor plug and remove the exhaust outlet cover or plug WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or dea...

Page 103: ...itional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the fol lowing responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the own...

Page 104: ...llow the water to drain com pletely Reinstall the drain plug 4 Start the engine Place the trans mission in neutral 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed then shift the trans mission into forward gear 7 Test for belt slippage If...

Page 105: ...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 poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk o...

Page 106: ...e battery out of the ATV 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 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 CAUTION If electr...

Page 107: ...ctions 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 jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Secure the battery hold down strap 8 Verify that cables are properly routed NOTE Cables...

Page 108: ...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 See page 119 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery...

Page 109: ...y the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter...

Page 110: ...standard 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 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At...

Page 111: ...th a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish CAUTION High water pressure may damage co...

Page 112: ...ealer 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 Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use...

Page 113: ...ent 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 periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the pr...

Page 114: ...d 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 and Filter Change the oil and filter See page 76 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Clean or replace the breather filter 4 Drain th...

Page 115: ...he machine so the engine is level or tilted slightly rearward 3 Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of engine oil into the cylinder 4 Reinstall the spark plug Torque to specification 5 Apply dielectric grease to the inside of the spark plug cap Reinstall the cap 6 Turn the engine over several times using the recoil starter Oil will be forced in and around the p...

Page 116: ...ightly off 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 condensation and may promote corrosion and oxi dation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris ...

Page 117: ... 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 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets ...

Page 118: ...stments 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 119: ... 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 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 injury or death Follow the adj...

Page 120: ...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 poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area Carburetor Engine Idle RPM Adjustment If the engine i...

Page 121: ...expose 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 adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut 6 Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position Lock Nut Adju...

Page 122: ...uid 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 Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease NyogelTM 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz Additi...

Page 123: ...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 engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Dr...

Page 124: ...el 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 switch is on Overuse of choke Inspect clean and or replace spark plugs Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failu...

Page 125: ...d 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 fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer...

Page 126: ...specs 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 filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Cause Sol...

Page 127: ... 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 Engine Model Number Type ES300PFE010 4 Cycle Single Cylinder Lubrication Wet sump Engine Cooling Air Displacement 299 cc Bore x Stroke 78 5 x 68 Alternator Output 250 w Compression Ratio 9 2 1 Carburetor Mikuni BST 3...

Page 128: ...g 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 40 F and above 5 C and above 0 900 0 3000 145 140 900 1800 3000 6000 Same main jet Remove 2 air box plugs 1800 2700 6000 9000 Same main jet Remove 4 air box plugs Above 2700 Above 9000 Same main jet Remove 6 a...

Page 129: ...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 Engine Model Number Type ES300PFE010 4 Cycle Single Cylinder Lubrication Wet sump Engine Cooling Air Displacement 299 cc Bore x Stroke 78 5 x 68 Alternator Output 250 w Compression Ratio 9 2 1 Carbureto...

Page 130: ...ghts 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 Meters Feet AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above 0 900 0 3000 145 140 900 1800 3000 6000 Same main jet Remove 2 air box plugs 1800 2700 6000 9000 Same main jet Remove 4 ...

Page 131: ...olaris dealer 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 No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed...

Page 132: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE ...

Page 133: ...e 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 issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the a...

Page 134: ...eling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show...

Page 135: ...red outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions c...

Page 136: ...f any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE A...

Page 137: ... 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 TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 138: ...135 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 139: ...119 Polishing the Vehicle 109 P Pre Ride Checklist 49 PVT Break In 48 PVT Drying 101 PVT System 100 101 R Recoil Housing 95 Recoil Starter 42 Reverse Operation 65 Reverse Override Switch 34 Rider Information Center 45 Riding Gear 10 11 S Safety Decals No Passenger Warning 8 Age 16 Warning 8 All Wheel Drive Switch 9 Clutch Cover Warning 9 Discretionary Warning 7 General Warning 6 Hitch Capacity Lab...

Page 140: ...orrosion Removal Chrome 110 Crankcase Emission Control 67 D Demand Drive Fluid 81 83 Drive Belt Wear Burn 120 Drivetrain Break In 48 Driving Downhill 59 Driving in Reverse 65 Driving on a Sidehill 58 Driving on Slippery Surfaces 56 Driving Over Obstacles 64 Driving Procedures 54 Driving Safely 54 66 Driving Through Water 62 63 Driving Uphill 57 E Electromagnetic Interference 67 Emissions Limited W...

Page 141: ...rque 91 Wheel Removal 90 Toe Alignment 87 Towing Loads 52 Training 13 Transmission Oil 78 80 Transporting the Vehicle 114 Turning Around on a Hill 60 61 Turning the Vehicle 55 V Vehicle Identification Numbers 5 Vehicle Immersion 98 W Warning Symbols 14 Washing the Vehicle 108 109 Wheel Hub Tightening 89 Wheel Installation 91 Wheel Nut Torque Specifications 91 Wheel Removal 90 ...

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Polaris Hawkeye 2X4 2007, Owner'S Manual

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