Polaris ATV repair manuals Polaris is an American manufacturer of snowmobiles, ATVs and electric vehicles. The company is based in Minnesota, although a portion of their vehicle assemblies are carried out in Mexico. 2017 Service Manual Pl pdf along with hundreds of other books into your. 2006 polaris hawkeye 300 4x4 manual, yamaha outboard manual 2017 115 owners. Shop Service Manuals in Maintenance at the Polaris Sportsman store. Warning: Polaris off-road vehicles can be hazardous to operate and are not intended for on-road use. Driver must be at least 16 years old with a valid driver’s license to operate. Passengers, if.

1. 2017 Polaris Hawkeye 300 4x4 Manual Transmission

. WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

A card containing important ATV safety information should be attached 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. RANGER utility vehicles. Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced. 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. Adjustments.115 Polaris Products. 119 Troubleshooting. 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. ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. Safety Decals and Locations Discretionary Warning WARNING.

Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually. REVERSE operation can be dangerous even at low speeds. SAFETY Safety Decals and Locations Age 16 Warning Rack Rack Warning Warning “No Passenger” Warning Clutch Cover Warning “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause 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. Safety Decals and Locations Clutch Cover Warning WARNING NO STEP.

2017 Polaris Hawkeye 300 4x4 Manual Transmission

Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death. Boots Helmet Wearing a helmet can prevent a severe head injury.

Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S.

Department of Transportation (DOT) label. 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. Failure to follow the warnings contained in this manual can result in 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. Operator Safety Safety Training ATV safety training is a top priority for Polaris.

When you purchased your new ATV, your dealer instructed you on the authorized ATV available to you and your eligible family members. This RiderCourse training is included in the purchase price of your ATV. Polaris strongly.

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. Never operate an ATV without proper instruction.

Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCourse. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident. Never operate on hills too steep for the ATV or for your abilities.

Operator Safety. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution to reduce the chance of skid- ding or sliding out of control.

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV.

WARNING offered by contact ATV Enrollment. Operator Safety POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the oper- ator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger. Operator Safety POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle.

HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's illegal to operate ATVs on public streets, roads and highways. Operator Safety POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seri- ously affect operator judgment. Reaction time may be slower and operator balance and per- ception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death. Operator Safety POTENTIAL HAZARD Attempting wheelies, jumps and other stunts.

WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. POTENTIAL HAZARD Failure to inspect the ATV before operating. Operator Safety POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.

If the operator's foot is not firmly planted on the footrest, it could contact the rear wheels and lead to accident or injury. Operator Safety POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slip- pery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slip- pery or loose terrain could cause loss of traction or loss of control, which could result in an accident or over- turn. SAFETY Operator Safety POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn.

HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees.

Operator Safety POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. SAFETY Operator Safety POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill.

If all forward speed is lost: Keep your weight uphill. Operator Safety POTENTIAL HAZARD Improperly operating over obstacles.

WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.

SAFETY Operator Safety POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water. HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Indus- tries Inc. Or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.

SAFETY Operator Safety POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Operator Safety Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Safe operation of this rider-active vehicle requires good judgement and phys- ical skills. FEATURES AND CONTROLS Switches Headlight Switch Mode/Reverse Override Switch 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 This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch. Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. NOTE: Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights. The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle.

Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding.

FEATURES AND CONTROLS Parking Brake Operating the ATV while the parking brake is engaged could result in an acci- dent and serious injury or death. Always check to be sure the parking brake is disengaged before operating.

Locking the Parking Brake 1. Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 50 for correct choke and throttle settings during start- ing. Fuel Tank Cap Fuel Tank Remove the fuel tank cap to add fuel to the fuel tank.

Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear N: Neutral R: Reverse Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake. 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. Grasp the recoil starter rope handle tightly. All Wheel Drive (AWD) System (4X4 Models) The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light in the instrument cluster will be When in AWD, the demand drive unit will automatically engage any.

Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to approximately 7-9 mph.

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.

Gear Indicator - This indicator displays gear shifter position. N = Neutral (Green) R = Reverse (Amber) 2. OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area.

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Break-In Period The break-in period for your new Polaris ATV 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 is as important as following the proce- dures for a proper break-in. OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Check the oil level on the dipstick.

Add oil if neces- sary to maintain the level between the safe and add marks. 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,. 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. Position the vehicle on a level surface. Place the transmission in neutral.

Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accu- mulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. ATV warranty.

Never install a hitch longer than 6 3/4' (17 cm). Never install automotive accessories on your Polaris ATV. Always install Polaris- approved (or equivalent) accessories designed for ATV use. CAUTION 6 3/4'. OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. OPERATION Driving Safely Driving Procedures 1.

Wear protective riding gear. Sit upright with both feet on the footrests and both hands on the handlebars.

Start the engine and allow it to warm up. Shift the transmission into gear. Driving Safely Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather, follow these precautions: 1. Slow down when enter- ing slippery areas. Engage AWD before wheels begin to lose traction. Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill.

Avoid steep hills (25° maximum). Keep both feet on the footrests. Shift your weight uphill. Proceed at a steady rate of speed and throttle opening. OPERATION Driving Safely Driving on a Sidehill (Sidehilling) 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 possible.

Follow proper procedures as outlined in the owner's manual. Driving Safely Driving Downhill Excessive speed when traveling downhill can cause loss of control and seri- ous injury or death. 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.

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. (2.4 m). Driving Safely Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. Leave the transmission in forward and shut off the engine. Dismount on the uphill side of the vehicle, or on the left if the vehi- cle is pointing straight uphill.

OPERATION Driving Safely Driving Through Water Maximum Depth Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before crossing. Driving Safely Driving Through Water After running the vehicle in water, it's critical to have it serviced as out- lined in the maintenance chart.

The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings. Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hid- den obstacle. Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: Your Polaris ATV is equipped with a reverse speed limiter. Use the override button with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1.

Stop the engine. Place the transmission in gear. Lock the parking brake. Always block the rear wheels on the downhill side. CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A.

Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on page 134. Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a ponent failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. (if equipped) 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) Hours Calendar Miles (Km).

Periodic Maintenance Chart Item 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 Spark plug. Spark arrestor Idle speed Toe adjustment 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) Hours Calendar Miles (Km) 100 H 12 M 1000 (1600) Inspect. Front Prop Shaft Yoke Control Arm (front and rear) Bearing Carrier Transmission (upper pivot point) Front Prop Shaft Yoke Lube Polaris Premium 4 Synthetic 0W-50 DOT 4 Only Polaris AGL Synthetic Gearcase Lube Premium Demand Drive Hub Fluid Polaris Premium U-Joint. 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.

Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the ATV. Position the vehicle on a level surface.

Place the transmission in neutral. Lock the parking brake. Start the engine. Allow it to idle for 30 seconds. MAINTENANCE Oil and Filter Change Hot oil can cause serious burns to skin.

Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. Always change the oil filter whenever changing oil. Oil and Filter Change 11. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove 12.

Clean the filter sealing area on the engine. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition. Chart beginning on page 68. Maintain the oil level at the bottom of the fill plug hole. See page 119 for the part numbers of Polaris products.

The fill plug is located on the left side of the ATV, under the rear fender, behind the wheel. Transmission Oil Oil Check 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. Remove the fill plug. Use a 15 mm wrench.

Check the oil level. Add oil as needed.

Do not overfill. Transmission Oil Oil Change 1. Position the vehicle on a level surface.

Place the transmission in gear. Lock the parking brake. Remove the fill plug. Use a 15 mm wrench. Place a drain pan under the gearcase. Periodic Maintenance Chart beginning on page 68.

Kawasaki vulcan 1600 mean streak repair manual. We recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of compo- nents. See page 119 for the part numbers of Polaris products. Front Gearcase (Demand Drive) Fluid Fluid Check 1.

Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. Remove the fill plug.

Use an 8 mm Allen wrench. Check the oil level. Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. Remove the fill plug.

Use an 8 mm Allen wrench. Place a drain pan under the gearcase. Do not overfill. If the fluid level is low add DOT 4 brake fluid only. See page 119 for the part numbers of Polaris products.

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Main- tain the fluid level 1/4' (6.3 mm) below the top edge of the master cylinder. Do not over- fill. Position the vehicle on a level surface. Make sure the handlebars are straight.

MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommended to keep the brake system in good operating condition. 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 String Rear of Front Rim. MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts.

If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. 1/8' (3 mm) or less.

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. MAINTENANCE WARNING 1/8' (3 mm). MAINTENANCE Tires Wheel Removal 1.

Position the vehicle on a level surface. Place the transmission in gear.

Lock the parking brake. Loosen the wheel nuts slightly. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. Always ensure that all nuts are torqued to specification.

Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Place the wheel on the wheel. MAINTENANCE Air Filter/Breather Filter 1. Position the vehicle on a level surface.

Place the transmission in gear. Lock the parking brake. Remove the seat. Release the air box cover clips, and remove the air box cover. Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. Position the vehicle on a level surface with the headlight approxi- mately 25 ft.

(7.6 m) from a wall. MAINTENANCE Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the housing before storing the vehicle. Make sure the hous- ing is completely dry before reinstalling the drain plug. Place the transmission in gear. Spark Plug Recommendations Using non-recommended spark plugs can result in serious engine damage.

Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 124 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Spark Plugs Spark Plug Inspection 4.

Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation. Reverse the procedure for spark plug installation.

Torque to specification. Spark Plug Condition Normal Spark Plug The normal insulator tip is gray, tan or light brown.

MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below. Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot.

Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Always follow all recommended maintenance procedures.

See your dealer as outlined in the owner's manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation. PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating.

Move the vehicle out of the water. Remove the PVT drain plug. Use a 17 mm wrench, a flat screw- driver, or the spark plug wrench.

Battery Your ATV may have either a sealed battery, which requires little mainte- nance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Battery 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. Battery Removal 1.

Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 106 before installing the battery. 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.

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 103. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action specified on top of battery) None, check at 3. Certain products, including insect repellents and chemicals, will damage plastic surfaces.

Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 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. 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. Make any necessary repairs and clean the vehicle as recommended. See page 108. Stabilize the Fuel 1. Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.

If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline. Accessories Auxiliary power outlets provide 12-volt power for operating accesso- ries. Accessory outlets are available for all models.

Polaris also has a wide range of additional accessories available for your ATV. Always install accessories that are approved for ATV use. Please see your Polaris dealer. Transporting the Vehicle Follow these procedures when transporting the vehicle. Stop the engine.

Place the transmission in gear. Lock the parking brake. Turn the fuel valve off. Secure the fuel cap, oil cap and seat. 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. Follow the adjustment procedures exactly, or see your Polaris dealer for service. Loosen the four handlebar bolts.

Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in. ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. Locate the throttle cable adjuster at the handlebar.

Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. Brake and Clutch Cleaner 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Brake Fluid (12 oz.) 2872893 Engine Degreaser (12 oz.) 2871956 Loctite 2871076 Polaris Battery Tender Engine Lubricant Additives / Miscellaneous 565 Thread Sealant Charger. Dry out the PVT. See page 101.

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.

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 Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark. 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. Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Overuse of choke Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel. 78.5 x 68 250 w 9.2:1 Mikuni BST 34 0-5M 4HC57-3 DC CDI 10° +/- 2° @ 1500 RPM/30° +/- 2° @ 5000 RPM NGK CR8EB /.031 in. (0.8 mm) Automatic PVT (Polaris Variable Transmission) Side Lever (H/N/R) 15.18:1. Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery DC Plug-In (rear) Windshield Speedometer/Odometer/ Tripmeter/Hourmeter Fuel Gauge Tool Kit Jetting Chart ALTITUDE Meters (Feet) 0-900 (0-3000) 900-1800 (3000-6000) 1800-2700 (6000-9000) Above 2700 (Above 9000).

299 cc 78.5 x 68 250 w 9.2:1 Mikuni BST 34 0-5M 4HC57-3 DC CDI 10° +/- 2° @ 1500 RPM/30° +/- 2° @ 5000 RPM NGK CR8E /.031 in.