2017 Hammerhead® R-150 - Hammerhead Off-Road

2017 Hammerhead® R-150 - Hammerhead Off-Road
2017 Hammerhead®
R-150
Owner's Manual
for Maintenance and Safety
1
POLARIS® and HAMMERHEAD® are trademarks of POLARIS Industries Inc.
Copyright 2016 POLARIS Industries Inc. All information contained within this
publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in
this publication. 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 expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
2017 R150 Owner’s Manual
P/N 9927515
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Emission Control Systems . . . . . . . . . . . . . . . 40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 83
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . 96
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3
INTRODUCTION
The R150 is an off-road vehicle. Familiarize yourself with all laws and
regulations concerning the operation of this vehicle in your area.
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
INTRODUCTION
WARNING
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your HAMMERHEAD vehicle is not a toy
and can be hazardous to operate. This vehicle handles differently than cars,
trucks or other off-road vehicles. 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 this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with the
vehicle.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and
have a valid driver’s license to operate this vehicle.
• No person under the age of 12 may ride as a passenger in this vehicle. All
riders must be able to sit with backs against the seat and both hands on the
steering wheel (if driving) or on a passenger hand hold.
• Always keep hands, feet and all other body parts inside the vehicle at all times.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants
and over-the-ankle boots.
• Do not operate this vehicle at night or during periods of limited visability.
• Never use this vehicle with drugs or alcohol, as these conditions impair
judgment and reduce operator reaction time.
• Complete the New Operator Driving Procedures outlined on pages 32-33.
Never allow a guest to operate this vehicle until the guest has watched the
instructional video and has completed the New Operator Driving Procedures.
5
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place.
Vehicle Identification Number
(On Frame Behind Driver Seat)
Engine Serial Number
(On Engine Case and Air Filter)
Manufacturing Data Label
(On Driver Side Floorboard)
Vehicle Model Number: ___________________________________________________
Vehicle Identification Number: ______________________________________________
Engine Serial Number: ___________________________________________________
Key Number ____________________________________________________________
6
SAFETY
Equipment Modifications
Your HAMMERHEAD vehicle is designed to provide safe operation when used
as directed.
WARNING! Modifying this vehicle in any way can change the top speed,
stability and handling performance of this vehicle. Modifications that increase
speed, decrease stability or change performance may present a greater risk to
inexperienced or younger operators and could result in loss of control and
serious injury or death. Use only HAMMERHEAD-approved accessories to
modify this vehicle. Review all vehicle changes prior to operating.
The HAMMERHEAD limited warranty on your HAMMERHEAD vehicle will be
terminated if any non-HAMMERHEAD-approved equipment and/or
modifications have been added to the vehicle that increase speed or power.
7
SAFETY
Safe Riding Gear
The driver and passenger must wear helmet, eye protection, gloves,
long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all
times. Protective gear reduces the chance of injury.
Helmet
Eye Protection
Long
Sleeves
Gloves
Long Pants
Over-the-Ankle
Boots
8
SAFETY
Safe Riding Gear
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding this
HAMMERHEAD 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.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
E4
of a circle surrounding the letter E, followed by the
051039
distinguishing number of the country which has
0006.31
granted approval. The approval number and serial
number will also be displayed on the label.
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding this HAMMERHEAD vehicle, always wear
shatterproof goggles or use a shatterproof helmet face shield.
HAMMERHEAD recommends wearing approved Personal Protective
Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
Make sure protective eye wear is kept clean.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and
other elements.
Boots
Wear sturdy over-the-ankle boots for support and protection. Never ride
a HAMMERHEAD vehicle with bare feet or sandals.
Clothing
Wear long sleeves and long pants to protect arms and legs.
Rider Comfort
Under certain operating conditions, heat generated by the engine and
exhaust system can elevate temperatures in the driver and passenger cab
area. The condition occurs most frequently when a vehicle is being
operated in high ambient temperatures at low speeds and/or high load
conditions for an extended period of time. The use of certain
windshield, roof and/or cab systems may contribute to this condition by
restricting airflow. Any discomfort due to heat buildup in this area can
be minimized by wearing proper riding apparel and by varying speeds to
increase airflow.
9
SAFETY
Safety Warnings
WARNING
Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual.
Be sure to read all of the following warnings about driving hazards and how to
avoid them. The hazards outlined in this section of this owner’s manual MUST
be avoided at all times. See the OPERATION section of this owner’s manual for
proper operating procedures.
Operating Without Instruction
Operating this vehicle without proper
instruction increases the risk of an accident.
The operator must understand how to operate
the vehicle properly in different situations and
on different types of terrain. Complete the New
Operator Driving Procedures outlined on
pages 32-33.
All operators must read and understand this
owner’s manual and all warning and
instruction labels before operating the vehicle.
Never allow a guest to operate this vehicle
until the guest has read this manual and all
product labels and has completed the New
Operator Driving Procedures outlined on
pages 32-33.
Operator Restrictions/Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16
years of age or anyone without a valid driver’s
license.
Never operate with a passenger under the age
of 12. All riders must be able to sit with backs
against the seat, both feet flat on the floor and
both hands on the steering wheel (if driving) or
on a passenger hand hold.
10
SAFETY
Safety Warnings
Rider Height
Some riders may be too tall to ride safely in
this vehicle. Do not operate or ride in this
vehicle if the clearance between the top of
your helmet and the brush bars is less than 2
inches (5 cm).
Minimum
2 in (5 cm)
Seat Belts
Riding in this vehicle without wearing the seat
belt increases the risk of serious injury in the
event of rollover, loss of control, other accident
or sudden stop. Seat belts may reduce the
severity of injury in these circumstances.
Riders must wear seat belts at all times.
Always make sure the seat belts are secured
for both the operator and passenger before
riding.
Using Alcohol or Drugs
Riding in this vehicle after consuming alcohol
or drugs could adversely affect operator
judgment, reaction time, balance and
perception.
Never consume alcohol or drugs before or
while operating or riding in this vehicle.
Failure to Inspect Before
Operating
Failure to inspect and verify that the vehicle is
in safe operating condition before operating
increases the risk of an accident.
Always inspect the vehicle before each use to
make sure it's in safe operating condition. See
page 28.
Always follow the inspection and maintenance
procedures and schedules described in this
owner’s manual. See page 41.
11
SAFETY
Safety Warnings
Protective Apparel
Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of serious injury in the event
of an accident.
Operator and passenger must always wear an
approved helmet that fits properly and eye
protection (goggles or face shield).
Carrying a Passenger
Never carry a passenger until you have
operated this vehicle for at least four hours
and have completed the New Operator Driving
Procedures outlined on pages 32-33.
Carrying Multiple Passengers
A passenger must always be seated in a passenger seat with seat belt secured.
Carrying more than one passenger in this vehicle can affect the operator’s ability
to steer and operate the controls, which increases the risk of loss of control and
accident or rollover. Never carry more than one passenger in this vehicle.
Operating on Pavement
This vehicle's tires are designed for off-road use only, not for use on pavement.
Operating this vehicle on paved surfaces (including sidewalks, paths, parking
lots and driveways) may adversely affect the handling of the vehicle and may
increase the risk of loss of control and accident or rollover. Avoid operating the
vehicle on pavement.
Operating on Public Roads
Operating this vehicle on public streets, roads
or highways could result in a collision with
another vehicle. Never operate this vehicle on
any public street, road or highway, including
dirt and gravel roads (unless designated for
off-highway use).
12
SAFETY
Safety Warnings
Operating at Excessive Speeds
Operating this vehicle at excessive speeds
increases the operator's risk of losing control.
Always operate at a speed that's appropriate
for the terrain, the visibility and operating
conditions, your skills and experience and
your passengers’ skills and experience.
Turning Improperly
Turning improperly could cause loss of
traction, loss of control, accident or rollover.
Always follow proper procedures for turning
as described in this owner’s manual.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
Jumps and Stunts
Exhibition driving increases the risk of an
accident or rollover. DO NOT do power slides,
“donuts”, jumps or other driving stunts. Avoid
exhibition driving.
Crossing Hillsides
Driving on a sidehill is not recommended.
Improper procedure could cause loss of
control or rollover. Avoid crossing the side of
any hill unless absolutely necessary.
If crossing a hillside is unavoidable, always
follow proper procedures as described in this
owner’s manual. See page 37.
Physical Control of the Vehicle
Removing hands from the steering wheel or hand holds or removing feet from
the floor while riding increases the risk of loss of control and accident or rollover.
The operator should always keep both hands on the steering wheel during
operation. A passenger should always be seated in the passenger seat with
both feet on the floor and with both hands securely grasping the hand holds.
Always keep hands and feet inside the vehicle at all times.
13
SAFETY
Safety Warnings
Driving Downhill Improperly
Driving down a hill improperly could cause loss
of control or rollover. Always follow proper
procedures for driving down a hill as described
in this owner’s manual. See page 37.
Improper Hill Climbing
Improper hill climbing could cause loss of
control or rollover. Use extreme caution when
operating on hills. Always follow proper
procedures for hill climbing as described in this
owner’s manual. See page 36. Never operate
the vehicle on hills steeper than 15 degrees.
Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a
hill could cause a rollover. Maintain a steady
speed when climbing a hill.
If you lose all forward speed:
Apply the brakes gradually until the vehicle is
fully stopped. Place the transmission in
reverse and slowly allow the vehicle to roll
straight downhill while applying light brake
pressure to control speed.
14
SAFETY
Safety Warnings
Operating in Unfamiliar Terrain
Failure to use extra caution when operating
on unfamiliar terrain could result in an
accident or rollover.
Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of
control or rollover.
Travel slowly and use extra caution when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions.
Operating on Sand or Slippery
Terrain
Operating on sand or on excessively rough,
slippery or loose terrain could cause loss of
traction, loss of control, accident or rollover.
Always use extra caution when operating on
sand or on rough, slippery or loose terrain. Do
not operate on excessively rough, slippery or
loose terrain.
Operating Improperly in
Reverse
Improperly operating in reverse could result in
a collision with an obstacle or person. Always
follow proper operating procedures as
outlined in this manual. See page 38.
Before shifting into reverse gear, always
check for obstacles or people behind the
vehicle. When it's safe to proceed, back
slowly.
Overloading the Vehicle
Overloading the vehicle or carrying/towing
loads may cause changes in stability and
handling, which could cause loss of control or
an accident.
• Never tow objects or carry loads over the
maximum cargo limit.
• Never exceed the maximum weight capacity
for this vehicle. See page 19.
15
SAFETY
Safety Warnings
Operating Over Obstacles
Improperly operating over obstacles could
cause loss of control or rollover.
Before operating in a new area, check for
obstacles. Never attempt to operate over
large obstacles such as large rocks or fallen
trees. Always follow the proper procedures
outlined in this manual when operating over
obstacles. See page 39.
Operating Through Water
Operating through deep or fast-flowing
water can cause loss of traction, loss of
control, rollover or accident. Never operate
in fast-flowing water or in water that exceeds
the floor level.
Always follow proper procedures for
operating in water as described in this
owner’s manual. See page 38.
Wet brakes may have reduced stopping
ability. After leaving water, test the brakes.
Apply them lightly several times while
driving slowly. The friction will help dry out
the pads.
Operating on Frozen Bodies of
Water
Operating on frozen bodies of water can
result in the vehicle and/or riders falling
through the ice. Never operate this vehicle
on a frozen body of water.
Improper Tires and
Maintenance
Operating this vehicle with improper tires or
with improper or uneven tire pressure could
cause loss of control, accident or rollover.
Always use the size and type of tires
specified for your vehicle. Always maintain
proper tire pressure as described in this
owner's manual and on safety labels.
16
SAFETY
Safety Warnings
Operating a Damaged Vehicle
Operating a damaged vehicle can result in an accident. After any rollover or
other accident, have a qualified service dealer inspect the entire machine for
possible damage, including (but not limited to) seat belts, rollover protection
devices, brakes, throttle and steering systems.
Refueling
Gasoline is highly flammable and is explosive under certain conditions. Always
exercise extreme caution whenever handling gasoline.
• Never allow a child to refuel or handle gasoline.
• Always stop the engine when refueling.
• Always refuel outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks in or near the refueling area or
where gasoline is stored.
• Never refuel while a person is in the vehicle.
• Do not over fill 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.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
Operate this vehicle only outdoors or in well-ventilated areas.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system.
Use caution when traveling through tall grass, especially dry grass. Always
inspect the underside of the vehicle and areas near the exhaust system after
driving through tall grass, weeds, brush and other tall ground cover. Promptly
remove any grass or debris clinging to the vehicle.
Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by
someone under the age of 16, without a drivers license, or without proper
training. This could result in an accident or rollover. Always remove the ignition
key when the vehicle is not in use.
17
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off,
contact your HAMMERHEAD dealer to purchase a replacement.
Replacement safety labels are provided by HAMMERHEAD at no
charge.
WARNING! This utility vehicle can be hazardous to operate if driven carelessly.
Injuries can result if you do not follow these instructions:
• Read owner’s manual and all labels before you operate this utility vehicle.
• Never operate this utility vehicle without proper instructions. Beginners require
adult supervision.
• Never operate this utility vehicle on public roads. It is intended for off-road use
only.
• Always wear an approved motorcycle helmet, eye protection and protective
clothing.
• Never operate this utility vehicle at excessive speeds. You increase your risk of
losing control if you operate it at speeds too fast for the terrain, visibility conditions or your experience.
• Never attempt wheelies, jumps, or other stunts.
WARNING! No Long Hair
All hair must be tied up and secured at or
above shoulder length. All loose clothing
must be secured. all necklaces and
scarves must be secured.
18
SAFETY
Safety Labels and Locations
WARNING! Loss of control, collision, or getting caught in moving parts can
result in serious injuries.
• No operation under age of 16 allowed.
• Wear a D.O.T. approved motorcycle helmet.
• Secure long hair and loose clothing.
• Wear protective eye wear and clothing.
• Keep arms, legs and feet inside the vehicle.
• Do not use alcohol or drugs.
WARNING!
• Moving parts can crush and cut.
• Keep hands clear.
• Do not operate with guards removed.
WARNING! Seat belt must be worn at all
times.
CAUTION! This vehicle manufactured
for off-road use only. Do not operate on
public streets, roads, or highways.
WARNING! No Riding
19
FEATURES AND CONTROLS
Component Locations
ABS
Plastic Top
Brush
Guards
Dump
Bed
Headlights
Parking
Brake
Shifter
Lever
LCD
Indicator
12V Auxiliary
Plug
Key
Ignition
20
Headlights
Horn/
Turn Signals
FEATURES AND CONTROLS
Seat Belts
This HAMMERHEAD vehicle is equipped with seat belts for all riders.
ALWAYS make sure the seat belts are secured for the operator and
passenger before riding.
3-Point Seat Belts
To wear the 3-point seat belts properly, do the following:
1. Hold the latch plate as you pull the belt across your lap and chest.
Make sure the belt is not twisted and is not caught on any portion of
the vehicle, your clothing, or any equipment you are carrying.
2. Push the latch plate into the buckle until it clicks. Pull up on the
latch plate to make sure it is secure.
3. Put the lap portion of the belt low on your hips. Push down on the
buckle end of the belt as you pull up on the shoulder part so the belt
is snug across your hips.
4. Position the shoulder belt over your shoulder and across your chest.
The shoulder belt should fit against your chest. If it is loose, pull the
belt out all the way and then let it retract.
5. To release the ubckle, firmly press the release button.
Seat Belt Inspection
Inspect all seat belts for proper operation before each use of the vehicle.
1. Push latch plates into the buckle until they click. The latch plates
must slide smoothly into the buckle. A click indicates that it's
securely latched.
2. Push the red release latch in the middle of the buckle to make sure it
releases freely.
3. Pull each seat belt completely out and inspect the full length for any
damage, including cuts, wear, fraying or stiffness. If any damage is
found, or if the seat belt does not operate properly, have the seat belt
system checked and/or replaced, Your dealer can assist.
4. To clean dirt or debris from the seat belts, sponge the straps with
mild soap and water. Do not use bleach, dye or household
detergents.Use a garden hose to flush out the retractor and latch
housings regularly.
21
FEATURES AND CONTROLS
Switches
Ignition Switch
The ignition switch is a three-position, key-operated switch. The key
can be removed from the switch when it is in the OFF position.
OFF
All electrical circuits are switched off. The key can be
removed in this position.
ON
All electrical circuits are supplied with power, and the
headlights and taillights are operable.
IGNITION
The electrical starter is engaged by turing and holding the key
in this position. Release the key when the engine starts.
CAUTION!
• Do not operate the electric starter continuously for more than 5 seconds, or damage may occur.
• Wait at least 5 seconds between each operation of the electric starter,
allowing it to cool.
• Do not commence the electric starter while the engine is running, or
damage may occur.
Light Switch
The ignition switch key must
be in the ON position to
operate the headlights. Press
the top of the rocker switch for
high beams. Press the bottom
of the rocker switch for low
beams.
22
High
Beam
Low
Beam
FEATURES AND CONTROLS
Auxiliary Outlet
The vehicle is equipped with a 12-volt accessory outlet on the dash. Use
the outlet to power an auxiliary light or other optional accessories or
lights. For service, the dash outlet connection is under the dash.
Horn
The vehicle is equipped with horn. To use, press in on horn tab.
23
FEATURES AND CONTROLS
Drive Select Lever
D: Drive
N: Neutral
R: Reverse
The drive select lever is used to
shift your vehicle into Drive,
Neutral, and Reverse (D, N, R).
Drive Select Lever
Tip: Sometimes it may be difficult to
select into the drive due to a
locked-up transmission. Move the
vehicle with your weight to unlock
the gears if this happens.
NOTICE: Do not attempt to shift the
transmission while the
vehicle is moving or damage
to the transmission could
result. Always shift when the vehicle is stationary and the engine is at
idle.
Parking Brake
The parking brake lever is located in between the driver seat and the
passenger seat. To operate the
parking brake, do the following.
•
To set the parking brake,
press the releas button and
pull up on the lever.
Parking Brake
5. To release the parking
brake, press the release button
and release the lever.
Tip: Always set the parking brake
whenever the vehicle is left
unattended.
WARNING! Operating the vehicle while the parking brake is engaged could
cause an accident resulting in serious injury or death. It could also result in
driveline or engine damage. Always be sure to disengage the parking brake
before operating the vehicle.
24
FEATURES AND CONTROLS
Brake Pedal
Depress the brake pedal to slow
or stop the vehicle. Apply the
brakes while starting the engine.
Throttle Pedal
Push the pedal down to increase
engine speed. Spring pressure
returns the pedal to the rest
position when released. Always
check that the throttle pedal
returns normally before starting
the engine. Make sure there's
adequate throttle pedal freeplay.
See page 60 for throttle pedal
adjustment procedures.
Throttle
Pedal
Brake
Pedal
Mechanical Speed Control System
The adjustable throttle limiting screw is located behind the throttle
pedal. Use the following procedure to control how far the throttle opens.
1. Remove limiter bolt.
2. Add washers underneath limiter bolt head until desired max speed is
reached.
Fuel Cap
The fuel tank is located
underneath the vehicle’s seat
bottom. Pull the vehicle’s seat
bottom up to reveal access to fuel
tank cap.
Fuel Cap
WARNING! Only use unleaded
grade gasoline.
25
OPERATION
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Vehicle Break-in Period
The break-in period for your new HAMMERHEAD vehicle is defined
as the first five (5) hours of operation.
No single action on your part is as important as a proper break-in period.
Careful treatment of a new engine and drive components will result in
more efficient performance and longer life for these components.
Perform the following procedures carefully.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.
Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute or
mix oil brands.
26
OPERATION
Vehicle Break-in Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. Always exercise extreme caution
whenever handling gasoline. See “Refueling” on page 17.
2. Check the oil level. See page 47. Add the recommended oil as
needed to maintain the oil level in the safe operating range.
3. Complete the New Operator Driving Procedures outlined on pages
32-33.
4. Avoid aggressive use of the brakes. See Brake System Break-in
below.
5. Vary throttle positions. Do not operate at sustained idle.
6. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 28.
7. Change the engine oil at five (5) hours.
8. Adjust and lubricate the drive chain at five (5) hours.
Brake System Break-in
Apply only moderate braking force for the first 50 stops. Aggressive or
overly forceful braking when the brake system is new could damage
brake pads and rotors.
CVT 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 clutches and belt by operating at
slower speeds during the break-in period as recommended. Avoid
aggressive acceleration and high speed operation during the break-in
period.
27
OPERATION
Pre-Ride Inspection
Failure to inspect and verify that the vehicle is in safe operating
condition before operating increases the risk of an accident. Always
inspect the vehicle before each use to make sure it's in safe operating
condition.
Item
Remarks
Page
Brake system/pedal travel
Ensure proper operation
25
61
Brake fluid
Ensure proper level
62
Front suspension
Inspect, lubricate if necessary
46
Rear suspension
Inspect, lubricate if necessary
46
Steering
Ensure free operation
63
Tires
Inspect condition and pressure
65
Wheels/fasteners
Inspect, ensure fastener tightness
66
Frame nuts, bolts, fasteners
Inspect, ensure tightness
Fuel and oil
Ensure proper levels
Grass and debris
Remove grass and debris from the
vehicle, especially on the underside
and near the exhaust system
Throttle
Ensure proper operation
Indicator lights/switches
Ensure proper operation
Air filter
Inspect and clean or replace
58
Daytime running lights
Ensure proper operation
67
Brake light
Ensure proper operation
-
Seat Latches
Move the seats forward and rearward
to ensure correct installation
21
Seat Belts
Check length of belt for damage,
check latches for proper operation
21
28
25
47
59
-
OPERATION
Safe Operation Practices
1. Visit the Recreational Off-Highway Vehicle Association web site
(rohva.org) and take the free on-line training course. Complete the
recommended safety training before operating this vehicle.
2. Do not allow anyone under 16 years of age or without a valid
driver’s license to operate this vehicle.
3. Never operate with a passenger under the age of 12. Never carry
more one passenger in a 2-seat vehicle. Never allow a passenger to
ride in the cargo box.
4. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
5. Never operate with accessories not approved by HAMMERHEAD
for use on this vehicle.
6. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt
and gravel roads.
7. Drive in a manner appropriate for your skills and operating
conditions. Never operate at excessive speeds. Never attempt
wheelies, jumps, or other stunts. Keep both hands on the steering
wheel during operation.
8. Never consume alcohol or drugs before or while operating this
vehicle.
9. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
10. Never operate a damaged vehicle. After any rollover or accident,
have a qualified service dealer inspect the entire machine for
possible damage.
11. Never operate the vehicle on a frozen body of water unless you have
first verified that the ice is sufficiently thick to support the weight
and moving force of the vehicle, you and your passenger, and your
cargo, together with any other vehicles in your party.
12. Do not touch hot exhaust system components. Always keep
combustible materials away from the exhaust system.
13. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
29
OPERATION
Starting the Engine
1.
2.
3.
4.
Sit in the driver’s seat and fasten the seat belt.
Place the transmission in neutral. Set the parking brake.
Apply the brakes.
If the engine is cold, use full choke by pulling the choke all the way
out. A warm engine will not require the use of the choke.
Tip: The choke is fully on when it’s pulled out. The choke is off when it’s completely pushed in. The choke can be adjusted gradually depending on how
much choke is needed for starting.
5. Do not press the throttle pedal while starting the engine.
6. Turn the ignition key past the ON/RUN position to START. Engage
the starter for a maximum of five seconds. Release the key when the
engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
7. If the engine does not start within five seconds, return the ignition
switch to the OFF position and wait five seconds. Repeat steps 6
and 7 until the engine starts.
8. Vary the engine RPM slightly with the throttle to aid in warm-up
until the engine idles smoothly.
9. Release the parking brake before driving.
30
OPERATION
Stopping the Engine
1.
2.
3.
4.
5.
Release the throttle pedal completely and brake to a complete stop.
Place the transmission in neutral.
Set the parking brake.
Stop the engine.
Turn key to off position
Braking
1. Release the throttle pedal completely. (When the throttle pedal is
released completely and engine speed slows to near idle, the vehicle
has no engine braking.)
2. Press on the brake pedal evenly and firmly. Practice starting and
stopping (using the brakes) until you're familiar with the controls.
Parking the Vehicle
1. Stop the vehicle on a level surface. When parking inside a garage or
other structure, be sure that the structure is well ventilated and that
the vehicle is not close to any source of flame or sparks, including
any appliance with pilot lights.
2. Place the transmission in neutral.
3. Set the parking brake.
4. Stop the engine.
5. Remove the ignition key to prevent unauthorized use.
31
OPERATION
New Operator Driving Procedures
1. Read and understand this owner's manual and all warning and
instruction labels before operating this vehicle.
2. Visit the Recreational Off-Highway Vehicle Association web site
(rohva.org) and take the free on-line training course. Hands-on
training is also available through ROHVA.
3. Review the section of this owner’s manual about starting the engine,
stopping the engine, braking and parking (pages 30-31).
4. Perform the pre-ride inspection (page 28).
5. The driver and passenger must wear helmet, eye protection, gloves,
long-sleeve shirt, long pants, over-the-ankle boots and seat belt at
all times.
6. Do not operate or ride in this
vehicle if the clearance between the
top of your helmet and brush bar is
Minimum
less than 2 inches (5 cm).
2 inches
(5 cm)
(continued on next page)
32
OPERATION
New Operator Driving Procedures
7. Select a level open area to practice driving. Make sure you have
permission to drive in this area.
8. Sit in the driver's seat and fasten the seat belt.
9. Make sure all passengers secure their seat belts.
10. Do not carry a passenger until you have at least four hours of
driving experience with this vehicle. See page 34.
11. Set the parking brake.
12. Place the transmission in neutral.
13. Start the engine. See “Starting the Engine” on page 30.
14. Apply the brakes and shift into gear.
15. Release the parking brake.
16. Check your surroundings. Make sure the area is clear of people and
obstacles.
17. Keeping both hands on the steering wheel, slowly release the brakes
and press the throttle with your right foot to begin driving.
18. Drive slowly at first. Practice starting, stopping, turning, using the
throttle and brakes and driving in reverse. Learn how the vehicle
handles when making both left and right turns at a slow speed.
19. Increase speed only after mastering all maneuvers at a slow speed.
20. After you become skilled at making turns and begin to operate at
faster speeds, follow these precautions:
• Avoid sharp turns. Make turns gradually.
• Never turn while applying heavy throttle.
• Never turn the steering wheel abruptly.
• Operate at speeds appropriate for your skills, the conditions and
the terrain.
• DO NOT attempt to do power slides, “donuts”, jumps or other
driving stunts.
33
OPERATION
Driving with a Passenger
1. Complete the New Operator Driving Procedures outlined on pages
32-33.
2. Perform the pre-ride inspection. See page 28.
3. Do not carry a passenger until you have at least four hours of
driving experience with this vehicle.
4. Make sure the passenger is at least 12 years of age. All riders must
be able to sit with backs against the seat, both feet flat on the floor
and both hands on the steering wheel (if driving) or on a passenger
hand hold.
5. Make sure the passenger has at least 2 inches (5 cm) of clearance
between his helmet and the brush bars.
6. Never carry more than one passenger in this vehicle.
7. Never allow a passenger to ride on the back of the vehicle. Allow a
passenger to ride only in the passenger seat.
8. Make sure the passenger is wearing helmet, eye protection, gloves,
long-sleeve shirt, long pants and over-the-ankle boots. See page 8.
9. Make sure the passenger secures the seat belt.
10. Tell your passenger to always keep hands and feet inside the vehicle
at all times.
11. Drive slowly. Vehicle handling may change with a passenger on
board. Always travel at a speed appropriate for your skills, your
passenger's skills, and operating conditions. Avoid unexpected or
aggressive maneuvers that could cause discomfort or injury to a
passenger.
12. Always follow all operating guidelines as outlined on safety labels
and in this manual.
34
OPERATION
Driving on Slippery Surfaces
When driving on slippery surfaces such as wet trails, loose gravel, sand
or ice, be alert for the possibility of skidding and sliding.
Follow these precautions when driving in slippery conditions:
1. Slow down before entering slippery areas.
2. Be alert, watch the path ahead and avoid quick turns, which can
cause skids.
3. Correct a skid by turning the steering wheel in the direction of the
skid. Never apply the brakes during a skid.
Sideways
skid
Turn in
direction of
skid
35
OPERATION
Driving Uphill
Whenever traveling
uphill, follow these
precautions:
1. Always check the
terrain carefully
before ascending a
hill. Never drive on
hills with
excessively slippery
or loose surfaces.
2. Avoid excessively
15° maximum
steep hills (15°
maximum).
3. Drive straight
uphill.
4. Drive at a steady rate of speed. Never press the throttle suddenly.
5. Avoid unnecessary changes in speed or direction.
6. Never go over the crest of a hill at a high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the
hill.
7. If the vehicle stalls while climbing a hill, apply the brakes. Place the
transmission in reverse and slowly allow the vehicle to roll straight
downhill while applying the brakes lightly to control speed.
36
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Driving on a sidehill
improperly cause loss of control or rollover.
If crossing a hill is unavoidable, follow these precautions:
1. Drive slowly and use extreme caution.
2. If the vehicle begins to roll over, or if it feels as if it may roll over,
immediately turn downhill.
3. Avoid obstacles and changes in terrain that may lower or raise one
side of the vehicle or cause the vehicle to slide.
4. If the vehicle begins to slide downhill, immediately turn downhill to
stop the slide, or stop the vehicle and maneuver slowly and
carefully until the vehicle can be driven straight downhill.
Driving Downhill
Whenever driving down a hill, follow these precautions:
1. Avoid excessively steep hills (15° maximum).
2. Slow down. Never travel down a hill at high speed.
3. Always check the terrain carefully before driving down a hill. Never
drive on hills with excessively slippery or loose surfaces.
4. Always drive down a hill with the transmission in forward gear.
Never “coast” or drive down a hill with the transmission in neutral.
5. Avoid driving down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Always drive straight downhill.
6. Apply the brakes lightly to keep speed slow.
37
OPERATION
Driving Through Water
Your vehicle can drive through shallow water. Make sure the water is no
deeper than the floor of the vehicle. Follow these precautions when
driving through water:
1. Check water depth. Never drive through water that is deeper than
the floor level.
2. After driving through water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the
pads.
NOTICE:
Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 41. Give special attention to
engine oil, transmission oil and all grease fittings.
If your vehicle becomes immersed or is operated in water that
exceeds the floor level, service is required before starting the
engine. Your HAMMERHEAD dealer can provide this service. If it's
impossible to bring the vehicle in before starting the engine, perform
the service outlined on page 68, and take the vehicle in for service at
the first opportunity.
Driving in Reverse
Follow these precautions when driving in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Apply the throttle lightly. Never apply the throttle suddenly.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid making sharp turns.
Parking on an Incline
A rolling vehicle can result in serious injury. Avoid parking on an
incline. If parking on an incline is unavoidable, follow these
precautions:
1. Place the transmission in neutral.
2. Set the parking brake.
3. Stop the engine.
4. Always block the rear wheels on the downhill side.
38
OPERATION
Driving Over Obstacles
Follow these precautions when driving over obstacles:
1. Always check for obstacles before driving in a new area.
2. Look ahead and watch the terrain. Always be alert for hazards such
as logs, rocks and low hanging branches.
3. Drive slowly and use extra caution when driving on unfamiliar
terrain. Obstacles are not always clearly visible.
4. Do not drive over large obstacles such as large rocks and fallen
trees. If it’s unavoidable, use extreme caution and drive slowly.
5. Always have a passenger dismount and move away from the vehicle
before driving over an obstacle that could cause a rollover.
39
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements and
local noise level requirements.
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.
40
MAINTENANCE
Periodic Maintenance Chart
Any qualified repair shop or person may maintain, replace or repair the
emission control devices or systems on your vehicle. An authorized
HAMMERHEAD dealer can perform any service that may be necessary
for your vehicle. HAMMERHEAD also recommends HAMMERHEAD
parts for emissions-related service, however equivalent parts can be
used.
It is a potential violation of the Clean Air Act if a part supplied by an
aftermarket parts manufacturer reduces the effectiveness of the vehicle’s
emission controls. Tampering with emission controls is prohibited by
federal law.
Owners are responsible for performing the scheduled maintenance
identified in this owner’s manual.
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, genuine
HAMMERHEAD parts are available from your HAMMERHEAD
dealer. Equivalent parts may be used for emissions-related service.
Record maintenance and service in the Maintenance Log beginning on
page 96.
Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, a
qualified dealer can perform these operations.
Vehicles subjected to heavy or severe use patterns must be inspected and
serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise.
Monitor the oil level, and if it continues to rise, discontinue use and
determine the cause. Your HAMMERHEAD dealer can assist.
41
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
Symbol
Description
Ź
Perform these operations more often for vehicles subjected to severe use.
D
Have an authorized HAMMERHEAD dealer or other qualified person perform these services.
WARNING! Improperly performing the procedures marked with a “D” could
result in component failure and lead to serious injury or death. Have an
authorized HAMMERHEAD dealer or other qualified person perform these
services.
42
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item
Maintenance Interval
(whichever comes first)
Hours Calendar
Miles
(Km)
Steering
-
-
Front suspension
-
-
Rear suspension
-
-
Tires
-
Brake fluid level
-
Daily
-
Brake pedal travel
-
-
Brake system
-
-
Wheels/fasteners
-
-
Frame fasteners
-
-
Engine oil level
-
-
Fuel Tank
Ź Air filter
Daily
-
Airbox Sediment
Tube
Daily
Remarks
Check each day before
driving the vehicle. Make
adjustments as needed.
See the Pre-Ride Checklist
on page 28.
Add Carbon Clean with each
fuel fill
-
Daily
Inspect; clean often; replace
as needed
Drain when deposits are
visible
Daytime running
lights/taillight
-
Daily
-
Check operation
Drive chain
-
Daily
-
Inspect; adjust, lubricate,
replace as needed
CVT housing (if
equipped)
-
Weekly
-
Drain water as needed,
check often if driving in wet
conditions
Ź Brake pad wear
D
10
Monthly
100 (160)
Inspect periodically
D Choke
(if equipped)
10
Monthly
100 (160)
Check for proper operation;
your dealer can assist
Idle Speed
10
Monthly
100 (160)
Check, adjust as needed
Valve Clearance
(Initial)
10
Monthly
100 (160)
Valve lash adjustment: Every
40 hours after first 10 hour
adjustment
5
Monthly
-
Perform a Break-in Oil
Change at one month
5
Monthly
-
Adjust and lubricate
Ź Engine oil change
(break-in)
Drive chain
(break-in)
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized HAMMERHEAD dealer or other qualified person perform these
services.
43
MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Hours Calendar
Fuel System
Battery
Remarks
(whichever comes first)
25
Monthly
Miles
(Km)
-
Inspect; check lines and
fittings for leaks and abrasion
25
Monthly
250 (400)
Check terminals; clean; test
Ź Main gearcase oil
25
Monthly
250 (400)
Inspect level; change yearly
Ź Engine breather
filter (if equipped)
25
1M
150 (250)
Inspect; replace if necessary
Ź Engine oil change
30
6M
300 (480)
Change Oil; Use 10w40 (SN)
Conventional Engine Oil
Ź General
lubrication
50
3M
500 (800)
Lubricate all fittings, pivots,
cables, etc.
Inspect, lubricate, adjust
50
6M
500 (800)
D Steering
Shift Linkage
50
6M
500 (800)
Lubricate
Ź Front Suspension
50
6M
500 (800)
Lubricate
Ź Rear Suspension
50
6M
500 (800)
Lubricate
D Choke Cable
50
6M
500 (800)
Inspect; adjust; lubricate;
replace if necessary. Your
dealer can assist.
Carburetor Float
Bowl
50
6M
500 (800)
Drain bowl periodically, and
prior to storage.
Carb Intake Ducts
50
6M
500 (800)
Inspect duct for proper
sealing/air leaks
D Valve Clearane
50
-
500 (800)
Adjust valve lash every 40
hours after first 10 hours
D Fuel system/filter
100
12 M
600 (1000) Inspect; Clean/Replace if
necessary. Check for leaks at
tank cap, filter, and carburetor.
Ź Spark plug
100
12M
600 (1000) Check, Replace as
necessary, torque to
specification
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized HAMMERHEAD dealer or other qualified person perform these
services.
44
MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Hours Calendar
Ź Engine mounts
Exhaust muffler/
pipe
Remarks
(whichever comes first)
Miles
(Km)
100
12 M
1000 (1600) Inspect
100
12 M
1000 (1600) Inspect
D Ignition timing
100
12 M
1000 (1600) Inspect
Ź Wiring
100
12 M
1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
D Clutches (drive
and driven)
100
12 M
1000 (1600) Inspect; clean; replace worn
parts
Drive belt
100
12 M
1000 (1600) Inspect; replace as needed
D Front wheel
bearings
100
12 M
1000 (1600) Inspect; replace as needed
D Brake fluid
200
24 M
2000 (3200) Change every two years
300
36 M
3000 (4800) Clean out
Spark arrester
D Toe adjustment
-
Inspect periodically; adjust
when parts are replaced
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized HAMMERHEAD dealer or other qualified person perform these
services.
45
MAINTENANCE
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 41, or more often under
severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.
Item
Engine Oil
Brake Fluid
Transmission Oil
(Main Gearcase)
Drive Chain
A-Arm Pivots
Ź Steering Arm
Pivots
Lube
10w40 Conventional
Engine Oil
DOT 4 Brake Fluid
AGL Gearcase Lubricant
& Transmission Fluid
Chain Lube or SAE 80/90
All Season Grease or
grease conforming to
NLGI No. 2
Method
See page 47.
See page 62.
See page 51.
See page 52.
Grease at general lubrication
interval, also after washing
vehicle or driving in water.
ŹPerform these procedures more often for vehicles subjected to severe use.
46
MAINTENANCE
Engine Oil
Oil Recommendations
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 41. HAMMERHEAD
recommends the use of 10w40 Conventional Engine Oil for this vehicle.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute or
mix oil brands.
Oil Check
Maintain the oil level within the
safe range on the dipstick. Do not
overfill.
1. Position the vehicle on a level
surface.
2. Remove the dipstick. Wipe it
dry with a clean cloth.
3. Reinstall the dipstick
completely.
4. Remove the dipstick and
check the oil level.
Dipstick
5. Add the recommended oil as
needed.
6. Reinstall the dipstick.
Drain Plug
Safe Range
{
Tip: A rising oil level between checks
in cool weather driving can
indicate contaminants such as
gas or moisture collecting in the
crankcase. If the oil level is over
the full/safe mark, change the oil
immediately.
Add Oil
Full
Fuel Filter
This vehicle is equipped with an in-line fuel filter. The filter should be
replaced at the intervals recommended in the Periodic Maintence Chart
beginning on page 41. Your dealer can assist.
NOTE: Do not attempt to clean the fuel filter.
47
MAINTENANCE
Engine Oil
Oil Change
1.
2.
3.
4.
Position the vehicle on a level surface. Set the parking brake.
Clean the area around the pre-filter plug.
Start the engine. Allow it to idle for two to three minutes.
Stop the engine.
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
5. Place a drain pan under the engine crankcase.
6. Remove the pre-filter plug. Allow the oil to drain completely.
7. Wash the oil pre-filter screen with solvent to remove debris. Allow
the screen to air dry.
48
MAINTENANCE
Oil Change
8. The external oil filter is located behind the driver’s seat in front of
the battery tray. The screw on the oil filter should be replaced when
oil is changed. With the oil drained from the crankcase, unscrew the
oil filter and replace with a new one. Ensure that the oil filter gasket
is properly seated, lubricated with oil and in good condition. Do not
over tighten the oil filter.
9. Clean the pre-filter plug. Install a new sealing washer on the plug.
The sealing surfaces on the plug and crankcase should be clean and
free of burrs, nicks or scratches.
10. Reassemble the pre-filter screen and spring to the pre-filter plug.
11. Reinstall the pre-filter drain plug. Torque to 14 ft. lbs. (19 Nm).
12. Remove the dipstick. Add 35.5 oz. (1050 ml) of the recommended
oil. Do not overfill. See the specifications section beginning on
page 79 for capacities.
13. Reinstall the dipstick.
49
MAINTENANCE
Oil Change
14. Start the engine. Allow it to idle for one to two minutes.
15. Stop the engine and inspect for leaks.
16. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
17. Dispose of used oil properly.
NOTICE: This vehicle comes with an external oil
cooler for the engine. Make sure to use
authentic replacements from your
preferred dealer.
Oil Cooler
50
MAINTENANCE
Transmission (Main Gearcase)
Always check and change the fluid at the intervals outlined in the
Periodic Maintenance Chart beginning on page 41. HAMMERHEAD
recommends the use of AGL Gearcase Lubricant & Transmission Fluid
for this vehicle.
Fluid Check
Fill Plug
The fill plug is located on the rear
of the gearcase. Maintain the fluid
level at the bottom of the fill
plug hole.
1. Position the vehicle on a level
surface.
2. Remove the fill plug.
3. Check the fluid level.
4. Add the recommended fluid as
needed.
5. Reinstall the fill plug.
Fluid Change
The drain plug is located on the right-hand side of the transmission.
1. Remove the fill plug.
2. Place a drain pan under the drain plug.
3. Remove the drain plug. Allow the fluid to drain completely.
4. Clean the drain plug.
5. Reinstall the drain plug with a new o-ring. Torque to 14 ft. lbs. (19
Nm).
6. Refill with .75 L/25 oz of recommended gear oil. Do not overfill.
7. Reinstall the fill plug.
8. Check for leaks.
9. Discard used fluid properly.
51
MAINTENANCE
Drive Chain Lubrication
Lubricate the drive chain with chain spray lube or an approved chain
lube at the general lubrication interval specified in the Periodic Maintenance Chart beginning on page 41. Lubricate more often under severe
use, such as in dirty or wet conditions.
NOTICE: Washing the drive chain with a high pressure washer or gasoline can
cause premature wear and drive chain failure. Don't use a high
pressure washer or gasoline to clean the drive chain.
Adjusting or operating the vehicle with improper rear drive chain
slack can result in severe damage to the transmission and drive
components. Always make sure the slack is within the stated
specifications.
Drive Chain Slack Adjustment
1. Loosen upper nut.
2. Turn lower nut clockwise in
1/2 turn increments, then turn
upper nut until tight. Follow
this procedure until chain is at
proper tension. Chain should
have 1/4” to 1/2” deflection.
3. Repeat the above steps until
chain is adjusted to desired fit.
52
Upper Nut
Lower Nut
MAINTENANCE
Parking Brake Adjustment
1. Inspect and perform any needed service on the brake pads before
adjusting the parking brake.
2. Position the vehicle on a level surface. Place the transmission in
neutral.
3. Carefully elevate the rear of the vehicle slightly. Use an appropriate
lift.
4. Loosen the jam nut on the parking brake
adjustment bolt.
5. While rotating the rear wheels by hand,
tighten the adjustment bolt until significant brake drag is detected. Then back
the adjustment bolt out 1/4 turn, or until
the wheel freely spins.
6. Hold the adjustment bolt in place and
tighten the jam nut securely against the
lever arm.
Adjustment Bolt
7. Check parking brake lever movement.
Verify that the rear wheels rotate freely
with the parking brake off (lever in DOWN position) and that the
vehicle will not move when the parking brake is applied (lever in
UP position).
8. Verify that the park brake lever stays in the UP position when the
brake is fully applied.
Parking Brake Cable Freeplay Adjustment
1. Inspect and perform any needed service on the brake pads before
adjusting parking brake cable freeplay.
2. Make sure the parking brake is NOT set (lever is DOWN).
3. Pull the brake cable back to inspect freeplay between the cable end
and the caliper bracket. Freeplay should be 1/16” - 1/8” (1.5-3 mm).
4. To adjust freeplay, loosen the jam
nut. Turn the in-line adjustment nut
outward to decrease freeplay. Turn
the adjustment nut inward to
increase freeplay.
5. Tighten the jam nut against the
adjustment nut.
Adjustment Nut
Jam Nut
53
MAINTENANCE
Spark Plug
Spark Plug Gap/Torque
Electrode Gap
0.6-0.7 mm
New Plug Torque
9-11 ft. lbs.
(12-15 Nm)
Used Plug Torque
17-20 ft. lbs.
(23-27 Nm)
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Use HAMMERHEAD-recommended spark plugs or their
equivalent. See page 79.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine is warmed up and
the vehicle is driven at higher speeds. Immediately check the spark plug
for correct color. See page 54.
A hot exhaust system and engine can cause burns. Wear protective
gloves when removing a spark plug for inspection.
Spark Plug Condition
Normal Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
Tip: The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect throttle body
adjustments.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended injection oil or incorrect throttle body
adjustments.
54
MAINTENANCE
Spark Plug
Spark Plug Removal and Replacement
1. Use a spark plug wrench to remove the spark
plug.
2. Inspect the spark plug each time you change the
oil. The electrodes should be kept clean and free
of carbon. The presence of carbon or excess oil
will reduce proper engine performance. If
possibe, check the spark plug gap (area between
electrodes) using a wire feeler gauge.
3. Before installing spark plug, coat threads lightly
with graphite grease if possible, to ensure easy
removal next time the spark plug needs
inspection.
4. Reverse the procedure for spark plug installation.
Torque to specification. See page 54.
NOTE: It is advisable to replace the spark plug at least
once a year to insure easy starting and good engine performance.
55
MAINTENANCE
Valve Adjustment Procedure
NOTE: In order to properly set the valves, the engine must be at TDC on the
compression stroke. To find TDC on the compression stroke, roll the
engine over until the intake valve closes and stop at TDC.
Intake Valve Clearance Adjustment
1. Remove the valve cover and secondary air pipr assembly.
2. Verify cam lobes are pointed down.
3. Insert correct thickness feeler gauge between end of intake valve
stem and adjuster screw.
4. When clearance is correct, hold adjuster screw and tighten locknut
securely.
5. Re-check the valve clearance.
6. Repeat adjustment procedure if necessary until clearance is correct
with locknut secured.
MEASUREMENT
Valve Clearance
0.004” (0.10 mm)
Exhaust Valve Clearance Adjustment
1. Remove the valve cover and secondary air pipr assembly.
2. Verify cam lobes are pointed down.
3. Insert correct thickness feeler gauge between end of exhaust valve
stem and adjuster screw.
4. Loosen locknut and turn adjuster screw until there is a slight drag on
feeler gauge.
5. When clearence is correct, hold adjuster screw and tighten locknut
securely,
6. Re-check the valve clearance.
7. Repeat adjustment procedure if necessary until clearance is correct
with locknut secured.
MEASUREMENT
Valve Clearance
0.0047” (0.12 mm)
56
MAINTENANCE
Constant Variable Transmission (CVT) System
WARNING
Failure to comply with the instructions in this warning can result in severe injury
or death.
Do not modify any component of the CVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The CVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The CVT 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 following
responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. See your HAMMERHEAD dealer, or other qualified person, for service and repair assistance.
• This CVT system is intended for use on HAMMERHEAD products only. Do not
install it in any other product.
• Always make sure the CVT housing is securely in place during operation.
CVT Drying
There may be some instances when water is accidently ingested into the
CVT system. Use the following instructions to dry it out before
operating.
1. Shift the transmission to neutral. Set the parking brake.
2. Start the engine. Apply varying throttle for 10-15 seconds to expel
the moisture and air-dry the belt and clutches. Do not hold the
throttle wide open for more than 10 seconds.
3. Allow the engine RPM to settle to idle speed.
4. Test for belt slippage. If the belt slips, repeat the process.
5. Your vehicle requires service as soon as possible. Your
HAMMERHEAD dealer can assist.
NOTICE: Exposure to salt water will cause corrosion to metal components. If
your vehicle is operated in salt water areas, rinse it off frequently with
fresh water.
57
MAINTENANCE
Filter Systems
Air Filter
Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 41.
1. The air filter box must be completely
Bolt
removed to access the air filter. To
remove, loosen the two (2) bolts
securing the box to the frame, as well as
the attached intake clamp.
1. Pull air filter box away from the
machine.
2. Loosen the five (5) screws on the outside
of the air filter box and remove the air
filter.
3. Remove the air cleaning element.
4. Remove and replace paper filter.
Intake Clamp
5. Apply a commercially available chassis
lubricant to the inside lip of the new air
filter. Install the filter and tighten the
clamp.
NOTICE: Never operate the vehicle with the filter
element removed. Dirt will enter the
engine, causing rapid wear and severe
damage to the engine.
6. Reinstall the access cover.
58
MAINTENANCE
Throttle System
WARNING
Failure to check or maintain proper operation of the throttle system can result in
an accident and lead to serious injury or death if the throttle pedal sticks during
operation.
Never start or operate this vehicle if it has a sticking or improperly operating
throttle pedal. Immediately contact your HAMMERHEAD dealer or other
qualified person for service if throttle problems arise. Always check the pedal for
free movement and return before starting the engine and occasionally during
operation.
Throttle Freeplay
If the throttle pedal has
excessive play due to cable
stretch or misadjustment, it will
cause a delay in throttle
response, especially at low
engine speed. The throttle may
also not open fully. If the
throttle pedal has no freeplay,
the throttle may be hard to
control, and the idle speed may
be erratic.
Check the throttle pedal
freeplay at the intervals
outlined in the Periodic
Maintenance Chart beginning
on page 41. Adjust the freeplay
if necessary.
Brake
Pedal
Throttle
Pedal
Throttle Freeplay Inspection
1. Place the transmission in neutral. Set the parking brake.
2. Start the engine. Allow it to warm up thoroughly.
3. Measure the distance the throttle pedal moves before the engine
begins to pick up speed.
59
MAINTENANCE
Throttle System
Throttle Freeplay Adjustment
Access the throttle cable adjuster
through the right front wheel
well.
1. Slide the cable adjuster boot
off the cable adjuster.
2. Squeeze the end of the
rubber boot and slide it far
enough to expose the end of
the in-line cable adjuster.
3. Loosen the adjuster lock nut.
4. Move the cable adjuster until
desired freeplay is achieved
at the throttle pedal. See
page 59. While adjusting,
lightly flip the throttle pedal
up and down.
5. Tighten the lock nut.
6. Apply a small amount of
grease to the inside of the
boot and slide it over the
cable adjuster to its original
position.
Boot
Lock Nut
Adjuster
60
MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc type brakes activated by the
brake pedal. See page 25.
Always check brake pedal travel and the brake fluid reservoir level
before each use of the vehicle. When applied, the brake pedal should
feel firm. Any sponginess would indicate a possible fluid leak or low
brake fluid level, which must be corrected before riding. See page 62 for
brake fluid information.
If you discover any irregularities in brake system operation, including
excessive pedal travel, contact your dealer for proper diagnosis and
repairs.
Operating the vehicle with a spongy brake pedal can result in loss of
braking, which could cause an accident resulting in severe injury or death.
Never operate the vehicle with a spongy-feeling brake pedal.
Brake Inspection
1. Check the brake system for fluid
leaks.
2. Check the brake pedal for
excessive travel or a spongy feel.
3. Check the brake pads for wear,
damage and looseness.
4. Inspect the brake pad wear
surface for excessive wear.
5. Change pads when the friction
material is worn to 0.04" (1
mm).
6. Check the surface condition of
the brake discs. Measure the
thickness of the front and rear
discs. Replace a disc if the
thickness is less than 1” (2.5
mm).
7. Check brake system hoses and
fittings for cracks, deterioration,
abrasion and leaks. Tighten any
loose fittings and replace any
worn or damaged parts.
Brake Pad
Rear Disc
Front Disc
61
MAINTENANCE
Brakes
Brake Fluid
Inspect the level of the brake fluid before each operation. If the fluid
level is low add DOT 4 brake fluid only.
After opening a bottle of brake fluid, always discard any unused portion.
Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of accident or severe injury.
Change the brake fluid every two
years and any time the fluid
becomes contaminated, the fluid
level is below the minimum, or if
the type and brand of the fluid in
the reservoir are unknown.
Access the brake fluid reservoir
through the front of the vehicle,
near the left headlamp.
1. Position the vehicle on a level
surface.
2. Place the transmission in
neutral. Set the parking
brake.
3. View the brake fluid level in
the reservoir. The level
should be between the
maximum and minimum
level lines. Add brake fluid
as needed.
4. Apply the brake forcefully
for a few seconds and check
for fluid leakage around the
fittings.
62
Maximum
Minimum
MAINTENANCE
Steering Wheel Inspection
Check the steering wheel for specified freeplay and smooth operation at
the intervals outlined in the Periodic Maintenance Chart beginning on
page 41.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. If there is excessive freeplay or strange noises, or the steering feels
rough or “catchy,” have the steering system inspected by an
authorized HAMMERHEAD dealer or other qualified service
facility before operating the vehicle.
Shock Spring Adjustment
The front and rear shock absorber springs are adjustable to increase or
decrease spring tension. There are five (5) adjustable positions on each
shock.
Use a round nut wrench to rotate
the adjuster to make adjustments.
The tension of the shock spring will
increase when turned left, and
decrease when turned right. Adjust
according to weight of the rider.
WARNING! Uneven adjustment may
cause poor handling of the vehicle,
which could result in an accident.
Always adjust both the left and right
spring preloads equally. Your dealer
can assist.
Adjuster
63
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8” to 1/4” (3-6 mm) toe out.
WARNING! Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments
should be performed by an authorized HAMMERHEAD dealer or other qualified
service facility.
1. Position the vehicle on a
level surface.
2. Set the steering wheel in a
straight-ahead position and
secure them in this position.
3. Place a chalk mark on the
center line of the front tires
as close to the hub/axle
center line as possible. Make
sure both marks are the same
distance from the floor.
4. Measure the distance between the marks and record the
measurement.
5. Move the vehicle to rotate the tires 180°. Position the wheels with
the chalk marks at the rear of the tires, even with the hub/axle center
line.
6. Measure the distance between the marks and record the
measurement.
7. Subtract the front dotted line from the back dotted line. The
difference is the vehicle toe-out alignment.
8. If you discover improper alignment, your preferred dealer can
assist.
64
MAINTENANCE
Tires
WARNING
Operating your vehicle with worn tires will increase the possibility of skidding,
loss of control and an accident, which could result in serious injury or death.
Always replace tires when the tread depth measures 1/8” (3 mm) or less.
Improper tire inflation or the use of non-standard size or type of tires may
adversely affect vehicle handling, which could result in vehicle damage or
personal injury. Always maintain proper tire pressure. Always use
HAMMERHEAD-approved size and type of tires for this vehicle when replacing
tires.
Tire Tread Depth
Always replace tires
when tread depth is worn
to 1/8” (3 mm) or less.
1/8" (3 mm)
Front Wheel Hub
Tightening
Front wheel bearing tightness and spindle nut retention are critical
component operations. All service must be performed by your
authorized HAMMERHEAD dealer or other qualified service facility.
Front Wheel Replacement
1. Position the vehicle on a
level surface.
2. Place the transmission in
neutral. Set the parking
brake. Stop the engine.
3. Loosen the wheel nuts
slightly.
4. Elevate the side of the
vehicle by placing a suitable
stand under the frame.
5. Remove the wheel nuts.
6. Remove the wheel.
7. Reverse steps to install.
65
MAINTENANCE
Tires
Rear Wheel Replacement
NOTE: Do not disassemble the castle nuts when you replace the rear wheel
and hub assembly.
1. Position the vehicle on a
level surface.
2. Place the transmission in
neutral. Set the parking
brake. Stop the engine.
3. Remove the cotter pin and
then 16mm nut.
4. Slide off wheel and hub
assembly. It is only
necessary to remove the 4
lug nuts to remove the wheel by itself.
Improperly installed wheels can adversely affect tire wear and vehicle
handling, which can result in serious injury or death. Always ensure that
all nuts are torqued to specification. Do not service axle nuts that have a
cotter pin installed. Your HAMMERHEAD dealer can assist.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been
loosened for service.
66
Location
Nut Torque
Front Wheel
45 ft-lbs +/- 5 ft-lbs (61 +/- 6.8 Nm)
Rear Wheel
45 ft-lbs +/- 5 ft-lbs (61 +/- 6.8 Nm)
MAINTENANCE
Lights
Headlamp Replacement
If the headlamps do not operate, replace the light assembly. Your dealer
can assist.
Tail Light Lamp Replacement
If the brakelight doesn't work, the lamp may
need to be replaced.
1. Remove the two screws securing the lens
cover.
2. Remove the lens cover.
3. Remove the lamp and replace it with a
new recommended lamp.
4. Test the light for proper operation.
5. Reinstall the lens cover.
67
MAINTENANCE
Vehicle Immersion
NOTICE: If your vehicle becomes immersed, major engine damage can result if
the machine is not thoroughly inspected. Take the vehicle in for
service before starting the engine. Your HAMMERHEAD dealer can
assist.
If it’s impossible to take your vehicle to a dealer before starting it,
follow the steps outlined below.
1. Move the vehicle to dry land.
2. Check the air box. If water is present, dry the air box and replace the
filter with a new filter. Thoroughly dry the air pre-filter. See page
58.
3. Remove the air box drain plug to drain any water. Reinstall the drain
plug securely.
4. Remove the spark plug.
5. Loosen carburetor drain screw.
6. Turn the engine over several times using the electric start.
7. Re-tighten the carburetor drain screw.
8. Dry the spark plug and reinstall it, or install a new plug.
9. Attempt to start the engine. If necessary, repeat the drying
procedure.
10. Take the vehicle in for service as soon as possible, whether you
succeed in starting it or not. Your HAMMERHEAD dealer can
provide the required service.
11. If water has been ingested into the transmission follow the
procedure on page 57 for drying.
68
MAINTENANCE
Battery
WARNING
Improperly connecting or disconnecting battery cables can result in an explosion
and cause serious injury or death. When removing the battery, always
disconnect the negative (black) cable first. When reinstalling the battery, always
connect the negative (black) cable last.
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 of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your vehicle may have either a sealed battery, which requires little
maintenance, 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.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire brush.
Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly. Be careful not to
allow cleaning solution or tap water into a conventional battery.
69
MAINTENANCE
Battery
Battery Removal
1. The battery can be accessed
from he rear of the vehicle,
behind the driver’s seat.
Remove strap and battery cover.
2. On conventional batteries,
remove the battery vent tube
(sealed batteries do not have a
vent tube).
3. Disconnect the negative battery
cable (green) first.
4. Disconnect the positive (red)
battery cable last.
5. Lift the battery out of the vehicle. Be careful not to tip a
conventional battery sideways, which could spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to the
vehicle.
Battery Installation
Using a new battery that has not been fully charged can damage the
battery and result in a shorter life. It can also hinder vehicle
performance. Follow the battery charging instructions on page 71 before
installing the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. Coat the terminals with dielectric grease or petroleum jelly.
4. Connect and tighten the red (positive) cable first.
5. Connect and tighten the black (negative) cable last.
6. Verify that cables are properly routed.
7. Put battery cover back on, and reattach strap.
70
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
Tip: Battery charge can be maintained by using a 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 predetermined point.
Battery Charging
The following battery charging instructions apply only to the
installation of a sealed battery. Read all instructions before proceeding
with the installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry 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.
An overheated battery may explode, causing severe injury or death.
Always watch charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool before resuming
charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8.
Tip: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use the
guidelines on the next page for recharging.
71
MAINTENANCE
Battery
Battery Charging
Always verify battery condition before and 1-2 hours after the end of
charging.
Charge Time
State of
Charge
Voltage
Action
(Using constant current
charger @ standard amps
specified on top of battery)
100%
12.8-13.0 volts
None required
75%-100%
12.5-12.8 volts
50%-75%
25%-50%
12.0-12.5 volts
11.5-12.0 volts
None, check at 3
mos. from date of
manufacture
May need slight
charge, if no
charge given,
check in 3 months
Needs charge
Needs charge
0%-25%
11.5 volts or less
72
Needs charge with
desulfating charger
3-6 hours
5-11 hours
At least 13 hours,
verify state of charge
At least 20 hours
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your HAMMERHEAD vehicle clean will not only improve its
appearance but it can also extend the life of various components.
Before washing the vehicle, locate the CVT inlet and outlet ducts. Avoid
spraying water directly toward the ducts.
NOTICE: Water in the CVT system could cause the drive belt to become wet
and slip in the clutches. Always avoid spraying water directly toward
the CVT inlet and outlet ducts.
High water pressure may damage components. HAMMERHEAD
recommends washing the vehicle by hand or with a garden hose,
using mild soap.
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 HAMMERHEAD vehicle is with
a garden hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with 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.
73
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and labels. Avoid directing the water stream at the
following items:
• Wheel bearings
• Radiator
• Transmission seals
• CVT inlet and outlet ducts
• Brakes
• Cab and body panels
• Labels and decals
• Electrical components and wiring
If an informational or graphic label becomes illegible or comes off,
contact your HAMMERHEAD dealer to purchase a replacement.
Replacement safety labels are provided by HAMMERHEAD at no
charge.
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
HAMMERHEAD recommends the use of common household aerosol
furniture polish for polishing the finish on your HAMMERHEAD
vehicle. Follow the instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• 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.
74
MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion,
preserve wheel life and ensure a “like new” appearance for many years.
Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are
more susceptible to corrosion if not properly cleaned. Clean chrome wheels
more often if they're exposed to salt or other corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. 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
polished chrome wheel. Choose a product suitable for chrome
finishes. Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as
outlined above.
75
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the protective
film created by fogging and damage could occur. Never start the
engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 73.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add Carbon Clean Fuel Treatment or equivalent fuel treatments or
stabilizers. Follow the instructions on the container for the
recommended amount. Carbon Clean removes water from fuel
systems, stabilizes fuel and removes carbon deposits from pistons,
rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes in a well ventilated area
to allow the stabilizer to disperse through the entire fuel delivery
system.
Air Filter / Air Box
Inspect and clean or replace the air filter. See page 58. Clean the air box.
Drain the sediment tube.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 41.
• Transmission fluid
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
Engine Oil
Change the oil. See page 48.
76
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 41.
Fog the Engine
1. Treat the fuel system with Carbon Clean or other equivalent fuel
treatment. Follow the instructions on the container. Start the engine.
Allow it to idle for several minutes so the Carbon Clean reaches the
carburetor. Stop the engine.
2. Remove the spark plug and add 2-3 tablespoons of engine oil. To
access the plug hole, use a section of clear 1/4” hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil.
3. Reinstall the spark plug. Torque to specification. See page 54.
4. Apply dielectric grease to the inside of the spark plug cap. Do not
reinstall the cap onto the plug at this step.
5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a
protective film of fresh oil.
6. If fuel system additive is not used, fuel tank, fuel lines, and injectors
should be completely drained of gasoline.
7. Reinstall the spark plug cap to the spark plug.
Battery Maintenance
See pages 71-72 for storage and charging procedures.
Storage Area/Covers
Be sure the storage area is well ventilated. Do not use plastic or coated
materials. They do not allow enough ventilation to prevent
condensation, and may promote corrosion and oxidation.
77
MAINTENANCE
Cleaning and Storage
Removal from Storage
1. Check the battery electrolyte level and charge the battery if
necessary. Install it in the vehicle. Make sure the battery vent hose is
routed properly and that it's not pinched or restricted in any way.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section
on page 28. Tightness of the bolts, nuts and other fasteners should
be checked by an authorized HAMMERHEAD dealer or other qualified service facility.
5. Lubricate at the intervals outlined in the Periodic Maintenance
Chart beginning on page 41.
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Place the transmission in neutral. Set the parking brake.
2. Stop the engine.
3. Remove the key to prevent loss during transporting.
4. Secure the fuel cap and seats. Ensure that the seats are attached
correctly and are not loose.
NOTICE: Always tie the frame of the HAMMERHEAD vehicle to the transporting
unit securely with suitable straps or rope. Do not attach tie straps to
the front control arm bolt pockets.
5. Wrap the front tie strap through the frame tubes, or attach a tiedown hook around each of the tubes.
6. Wrap the rear tie strap around the swing arm.
78
SPECIFICATIONS
R 150
Engine
Drivetrain
Chassis
Tires
Engine/Motor Type
Displacement
Cooling
Starting
Fuel System
Fuel Capacity
Fuel Type
Engine Oil Capacity
Engine Oil Type
Spark Plug Type
Drive/Clutch
Drive Type
Transmission/Transaxle
Driveline
Front Suspension
Rear Suspension
Steering
Front Brake
Rear Brake
Seats
Seat belt
Body
Front Tires
Rear Tires
Wheels
Operating Tire Pressure Front
Operating Tire Pressure Rear
4-Stroke
149cc
Air
Electric
Carburetor
1.75 Gal
Unleaded. Never use fuel with
higher than 10% ethonal.
35.5 oz. (1050 ml)
SAE-10W/40
CR7HSA (NGK)
Automatic CVT
2-Wheel Drive
F/N/R
Dual Chain
Dual A-Arm
Swing Arm
Rack & Pinion
Hydraulic Disc (2)
Hydraulic Disc
Bench
3-Point Harness
Brush Guard
22x7-10
22x10-10
Steel (Black)
10 PSI
10 PSI
79
SPECIFICATIONS
R 150
Dimensions
Capacity
Weight
80
Length
Width
Height
Wheelbase
Ground Clearance
Bed/Rack Dimensions L x W x H
Distance Seat to Pedal (Front Edge)
Distance Seat to Pedal (Seat Back)
Bed/Rack Capacity
Towing Capacity
Vehicle Capacity
Fuse
Battery
Dry Weight
95”
51”
74”
67”
6.5”
38” x 23” x 11”
N/A
N/A
250 lbs
500 lbs
800 lbs
15A
12V / 9 Amp Hours
700 lbs
SPECIFICATIONS
ENGINE TUNE-UP SPECIFICATION
Idle Mixture
Intake Valve Clearance
Exhaust Valve Clearance
Spark Plug
Spark Plug Gap
Ignition Timing
Idle Speed
Fuel
Oil
Non-Adjustable
0.04” (0.1 mm)
0.0047” (0.12 mm)
CR7HSA (NGK)
0.6 - 0.7 mm
Non-Adjustable
1700 +/- 100 RPM in Neutral
Unleaded Gasoline Only
87 (R+M)/2 Octane or Higher
10W 40
81
SPECIFICATIONS
Jetting Chart
Carburetor Jetting
Carburetor Jetting Chart for Altitude and Ambient Temperature Changes
ALTITUDE
Feet
(Meters)
0-2000
(0-600)
2000-4000
(600-1200)
4000-6000
(1200-1800)
6000-8000
(1800-2400)
8000-10000
(2400-3000)
Above
10000
(Above
3000)
82
AMBIENT TEMPERATURE
°F:
°C:
Main Jet
Pilot Jet
Needle
Main Jet
Pilot Jet
Needle
Main Jet
Pilot Jet
Needle
Main Jet
Pilot Jet
Needle
Main Jet
Pilot Jet
Needle
Main Jet
Pilot Jet
Needle
Below -25
-30 to -10
-15 to +5
0 to +20
Below -31
-34 to -23
-26 to -15
-18 to -7
+15 to +35 +30 to +50 +45 to +65 Above +60
-9 to +2
-1 to +10
+7 to +18
Above +16
112
38
2 shims
112
38
2 shims
111
35
1 shim
111
35
1 shim
110
35
1 shim
110
35
1 shim
112
38
2 shims
112
38
2 shims
111
35
1 shim
111
35
1 shim
110
35
1 shim
110
35
1 shim
112
38
2 shims
112
38
2 shims
111
35
1 shim
111
35
1 shim
110
35
1 shim
110
35
1 shim
112
38
2 shims
112
38
2 shims
111
35
1 shim
111
35
1 shim
110
35
1 shim
110
35
1 shim
111
35
1 shim
111
35
1 shim
110
35
1 shim
110
32
No shim
109
32
No shim
109
32
No shim
111
35
1 shim
111
35
1 shim
110
35
1 shim
110
32
No shim
109
32
No shim
109
32
No shim
111
35
1 shim
111
35
1 shim
110
35
1 shim
110
32
No shim
109
32
No shim
109
32
No shim
111
35
1 shim
111
35
1 shim
110
35
1 shim
110
32
No shim
109
32
No shim
109
32
No shim
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause
Solution
Driving at low RPM or
ground speed
Drive at a higher speed.
Insufficient warm-up at
low ambient temperatures
Warm the engine at least 5 minutes. With the transmission
in neutral, apply small amount of throttle in short bursts, 5
to 7 times. The belt will become more flexible and
prevent belt burning.
Slow/easy clutch engage- Use the throttle quickly and effectively.
ment
Belt slippage from water
or snow ingestion into the
CVT system
Dry out the CVT (see page 57). Prevent water from
entering the CVT inlet and outlet ducts (see page 73).
Inspect clutch seals for damage if repeated leaking
occurs.
Clutch malfunction
Your HAMMERHEAD dealer can assist.
Poor engine performance
Check for fouled plug or foreign material in gas tank, fuel
filter, and fuel lines. Your HAMMERHEAD dealer can
assist.
Wrong or missing belt
Install the recommended belt.
Improper break-in
Always break in a new belt and/or clutch. See page 26.
83
TROUBLESHOOTING
Engine Doesn't Turn Over
Possible Cause
Low battery voltage
Loose battery connections
Loose solenoid connections
Solution
Recharge the battery to 12.8 VDC
Check all connections and tighten
Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause
Out of fuel
Water is present in fuel
Old or non-recommended fuel
Fouled or defective spark plug
No spark to spark plug
Water or fuel in crankcase
Clogged fuel filter
Low battery voltage
Mechanical failure
Solution
Refuel
Drain the fuel system and refuel
Replace with fresh recommended fuel
Inspect plug and replace if necessary
Inspect plug and replace if necessary
Your HAMMERHEAD dealer can assist.
Inspect plug and replace if necessary
Recharge the battery to 12.8 VDC
Your HAMMERHEAD dealer can assist.
Engine Backfires
Possible Cause
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Mechanical failure
Loose ignition connections
Water present in fuel
Exhaust system leak
84
Solution
Inspect, clean and/or replace spark plug
Set gap to specs or replace plug
Replace with fresh recommended fuel
Your HAMMERHEAD dealer can assist.
Your HAMMERHEAD dealer can assist.
Your HAMMERHEAD dealer can assist.
Check all connections and tighten
Replace with fresh recommended fuel
Your HAMMERHEAD dealer can assist.
TROUBLESHOOTING
Engine Pings or Knocks
Possible Cause
Poor quality or low octane fuel
Incorrect ignition timing
Incorrect spark plug gap or heat range
Solution
Replace with recommended fuel
Your HAMMERHEAD dealer can assist.
Set gap to specs or replace plug
Engine Runs Irregularly, Stalls or Misfires
Possible Cause
Fouled or defective spark plug
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Water present in fuel
Low battery voltage
Clogged fuel cap vent
Incorrect fuel
Clogged air filter
Throttle control malfunction
Other mechanical failure
Possible Lean Fuel Cause
Low or contaminated fuel
Low octane fuel
Clogged fuel filter
Incorrect fuel
Possible Rich Fuel Cause
Fuel is very high octane
Stopping/starting without adequate
warm-up
Incorrect fuel
Clogged air filter
Solution
Inspect, clean and/or replace spark plug
Your HAMMERHEAD dealer can assist.
Set gap to specs or replace plug
Check all connections and tighten
Replace with new fuel
Recharge battery to 12.8 VDC
Inspect and replace
Replace with recommended fuel
Inspect and clean or replace
Your HAMMERHEAD dealer can assist.
Your HAMMERHEAD dealer can assist.
Solution
Add or change fuel, clean the fuel system
Replace with recommended fuel
Your HAMMERHEAD dealer can assist.
Replace with recommended fuel
Solution
Replace with lower octane fuel
Allow engine to warm up before operating and/or stopping
Replace with recommended fuel
Inspect and clean or replace
85
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Out of fuel
Clogged fuel cap vent
Water is present in fuel
Fouled or defective spark plug
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Low battery voltage
Incorrect fuel
Clogged air filter
Throttle control malfunction
Other mechanical failure
86
Solution
Refuel
Inspect and replace
Replace with new fuel
Inspect, clean and/or replace spark plug
Your HAMMERHEAD dealer can assist.
Set gap to specs or replace plug
Check all connections and tighten
Recharge the battery to 12.8 VDC
Replace with fresh recommended fuel
Inspect and clean or replace
Your HAMMERHEAD dealer can assist.
Your HAMMERHEAD dealer can assist.
WARRANTY
Limited Warranty
HAMMERHEAD Inc., 1200 Lakeside Parkway Ste. 400 Flower Mound, TX 75028
(HAMMERHEAD) provides a ONE HUNDRED and EIGHTY DAY PARTS ONLY
LIMITED WARRANTY against defects in material or workmanship for all vehicle
frames and engines. This PARTS ONLY LIMITED WARRANTY covers parts charges
for repair or replacement of defective parts but does not cover any related labor charges
or expense.
HAMMERHEAD provides a NINETY DAY PARTS AND LABOR LIMITED
WARRANTY against defects in material or workmanship for all other components,
except those consumable, general wear, and exposed to friction components referenced
in the following paragraph. This NINETY DAY LIMITED WARRANTY covers parts
and labor charges for repair or replacement of defective parts.
HAMMERHEAD provides a THIRTY DAY LIMITED WARRANTY against defects in
material or workmanship on all consumable components, general wear items, or any
parts exposed to friction surfaces, stresses, environmental conditions and/or
contamination for which they were not designed or not intended; including but not
limited to the following items:
•
•
•
•
•
•
•
•
•
•
•
•
Wheels and Tires
Suspension Components
Brake Components
Seat Components
Clutches and Components
Steering Components
Batteries
Light Bulbs/ Sealed Beam Lamps
Filters
Lubricants
Bushings
Cables
•
•
•
•
•
•
•
•
•
•
•
•
Finished and Unfinished Surfaces
Carburetor/Throttle Body Components
Engine Components
Drive Belts
Hydraulic Components and Fluids
Circuit Breakers/Fuses
Electronic Components
Spark Plugs
Sealants
Coolants
Bearings
Vehicle Tops
This THIRTY DAY LIMITED WARRANTY covers parts and labor charges for repair
or replacement of defective parts.
The duration of these warranties may vary by international region based upon local laws
and regulations. These warranties begin on the date of purchase by the original retail
purchaser.
Registration
IMPORTANT!
ALL UNITS MUST BE REGISTERED WITHIN 14 DAYS OF PURCHASE.
To register your product a copy of the Warranty Registration Form and sales receipt
must be forwarded to HAMMERHEAD Off-Road. Your dealer, with your assistance,
will complete and forward these items to HAMMERHEAD Off-Road. A copy of the
Warranty Registration Card and Buyer Safety Agreement is attached. It is your responsibility to confirm with your dealer within 14 days of purchase that your product has been
registered. If you are unable to confirm with your dealer within 14 days of purchase that
your product has been registered please contact HAMMERHEAD Off-Road within 14
days of purchase.
87
WARRANTY
Warranty Coverage And Exclusions:
Limitations Of Warranties And Remedies
This HAMMERHEAD limited warranty excludes any failures that are not caused by a
defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS
OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental
damage, normal wear and tear, abuse or improper handling. This warranty also does not
cover any vehicle, component, or part that has been altered structurally, modified,
neglected, improperly maintained or used for racing, competition or purposes other than
for which it was designed.
This warranty excludes damages or failures resulting from: improper lubrication;
improper engine timing; improper fuel; surface imperfections caused by external stress,
heat, cold or contamination; operator error or abuse; improper component alignment,
tension, adjustment or altitude compensation; snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket or unapproved components, accessories, or attachments; unauthorized
repairs; or repairs made after the warranty period expires or by an unauthorized repair
center.
This warranty excludes damages or failures caused by abuse, accident, fire, or any other
cause other than a defect in materials or workmanship and provides no coverage beyond
the 180, 90, or 30 day period set forth above
Lubricants and Fluids
1. Mixing oil brands or using non-recommended oil may cause engine damage.
2. Damage or failure resulting from the use of non-recommended lubricants or fluids is
not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including mileage,
transportation costs, hotels, meals, shipping or handling fees, product pick-up or
delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or
personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT
HAM-MERHEAD'S OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE
MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN
THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON
FOR BREACH OF THIS WARRANTY. HAMMERHEAD SHALL HAVE NO
LIABILITY TO ANY PERSON FOR IN-CIDENTAL, CONSEQUENTIAL OR
SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,
NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF
CONSEQUENTAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT
FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY
FAILED OF ITS ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS
EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED
WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTY OF MERCHANTABILITY) ARE LIM-ITED IN DURATION TO THE
ABOVE WARRANTY PERIODS. HAMMERHEAD DIS-CLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT
PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION
OF IM-PLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY
TO YOU IF IN-CONSISTENT WITH CONTROLLING STATE LAW.
88
WARRANTY
How To Obtain Warranty Service
If your vehicle requires warranty service, you must take it to a HAMMERHEAD
Servicing Dealer. When requesting warranty service you must present your copy of the
Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO
AND FROM THE DEALER IS YOUR RESPONSIBILITY.) HAMMERHEAD
suggests that you use your original selling dealer; however, you may use any
HAMMERHEAD Servicing Dealer to perform warranty service.
In the Country where your product was purchased:
Warranty or Service Bulletin repairs must be done by an authorized HAMMERHEAD
dealer. If you move or are traveling within the country where your product was
purchased, Warranty and Service Bulletin repairs may be requested from any authorized
HAMMERHEAD dealer that sells the same line as your product.
Outside the Country where your product was purchased:
If you are traveling temporarily outside the country where your product was purchased,
you should take your product to an authorized HAMMERHEAD dealer. You must show
the dealer photo identification from the country of the selling dealer's authorized
location as proof of residence. Upon residence verification, the servicing dealer will be
authorized to perform the warranty repair.
If you move:
If you move to another country, be sure to contact HAMMERHEAD Customer
Assistance and the customs department of the destination country before you move.
Product importation rules vary considerably from country to country. You may be
required to present documentation of your move to HAMMERHEAD in order to
continue your warranty coverage. You may also be required to obtain documentation
from HAMMERHEAD in order to register your product in your new country. You
should warranty register your product at a local HAMMERHEAD dealer in your new
country immediately after you move to continue your warranty coverage and to ensure
that you receive information and notices regarding your vehicle.
If you purchase from a private party:
If you purchase a HAMMERHEAD product from a private party, to be kept and used
outside of the country in which the product was originally purchased, all warranty
coverage will be denied. You must nonetheless register your product under your name
and address with a local HAMMERHEAD dealer in your country to ensure that you
receive safety information and notices regarding your product.
Exported Products
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO
WARRANTY OR SERVICE BULLETIN COV-ERAGE ON THIS PRODUCT IF IT IS
SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED
LOCATION. This policy does not apply to products that have received authorization for
export from HAMMERHEAD. Dealers may not give authorization for export. You
should consult an authorized dealer to determine this product's warranty or service
coverage if you have any questions. This policy does not apply to products registered to
government officials or military personnel on assignment outside the country of the
selling dealer's authorized location. This policy does not apply to Safety Bulletins.
89
WARRANTY
Notice
If your product is registered outside of the country where it was purchased and you have
not followed the procedure set above, your product will no longer be eligible for
warranty or service bulletin coverage of any kind, other than safety bulletins. Products
registered to government officials or military personnel on assignment outside of the
country where the product was purchased will continue to be covered by the Limited
Warranty.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance, they will contact the appropriate person at HAMMERHEAD.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state or in different countries. If any of the above terms are void
because of federal, state, local law, all other warranty terms will remain in effect.
For questions call HAMMERHEAD Customer Assistance:
United States & Canada: 214-513-1700RUWROOIUHHDW
90
WARRANTY
Emissions Control System Limited Warranty
This Emissions Control System Limited Warranty for your engine is provided by Polaris
Sales Inc. (PSI). It is administered by HAMMERHEAD Off-Road Inc. on behalf of PSI.
This Emissions Control System Limited Warranty is in addition to the HAMMERHEAD
Off-Road Inc. standard limited warranty for your vehicle. HAMMERHEAD Off-Road
Inc. is hereinafter referred to as HAMMERHEAD in the remainder of this Emission
Control System Limited Warranty.
YOUR WARRANTY RIGHTS AND OBLIGATIONS
Your new spark-ignited small off-road engine must be designed, built, and equipped to
meet applicable U.S. EPA emission standards.
HAMMERHEAD warrants the emission control system on your small off-road engine
for the 2-year period of time listed below, provided there has been no abuse, neglect, or
improper maintenance of your power equipment engine. Where a warrantable condition
exists, HAMMERHEAD will repair your small off-road engine at no cost to you
including diagnosis, parts, and labor.
Your emission control system may include parts such as the carburetor or fuel injection
system, fuel lines, hoses, connectors, the ignition system, catalytic converter, and other
emissions-related assemblies (see the WARRANTY COVERAGE section below for
more information on the covered parts).
OWNER’S WARRANTY RESPONSIBILITIES
Owners are responsible for performing all required maintenance identified in the
owner's manual. HAMMERHEAD recommends that all receipts covering the
maintenance of your small off-road engine are retained, but HAMMERHEAD cannot
deny warranty solely for the lack of receipts or for your failure to ensure that all
scheduled maintenance has been completed.
HAMMERHEAD may deny warranty claims for failures that have been caused by the
owner's or operator's improper maintenance or use, by accidents for which
HAMMERHEAD has no responsibility, or by acts of God.
You are responsible for presenting your small off road engine to a HAMMERHEAD
dealer, a qualified repair shop, or qualified individual as soon as a problem exists.
For any questions regarding your warranty rights and responsibilities, contact
HAMMERHEAD at the following:
Hammerhead Off-Road Inc.
1200 Lakeside Parkway #400
Flower Mound, TX 75028
Telephone: 214-513-1700
RU toll-free at 1-800-275-1701
Fax: 214-513-1711
Email: [email protected]
91
WARRANTY
Emissions Control System Limited Warranty
WARRANTY COVERAGE
HAMMERHEAD warrants to the ultimate purchaser and each subsequent purchaser
that, at the time it is first purchased, this emissions-certified engine is designed, built,
and equipped so it conforms to applicable U.S. Environmental Protection Agency
emission regulations. HAMMERHEAD warrants that the engine is free from defects in
materials and workmanship that would cause it to fail to meet these regulations.
The emissions control system of your engine is covered by this warranty for a period of
two years, beginning on the date the engine or small-off road vehicle equipped with the
engine is sold to the ultimate purchaser. This warranty is transferable to each subsequent
purchaser for the duration of the warranty period. This EPA emissions warranty period is
extended for at least as long as the standard factory warranty that HAMMERHEAD
provides on the engine as a whole. The EPA emissions warranty period does not further
extend if additional warranty coverage in the form of a service contract or other paid
warranty extension is purchased, but emission-related parts may be covered subject to
the terms of any such paid service contract or paid warranty extension.
This emissions limited warranty covers components whose failure increases the
vehicle's regulated emissions, and it covers components of systems whose only purpose
is to control emissions. Repairing or replacing other components not covered by this
warranty is the responsibility of the vehicle owner. This emissions limited warranty does
not cover components whose failure does not increase the vehicle's regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to
the following systems:
• Air-induction system
• Fuel system
• Ignition system
• Exhaust gas recirculation systems
The following parts are also considered emission-related components for exhaust
emissions:
• After-treatment devices
• Crankcase ventilation valves
• Sensors
• Electronic control units
The following parts are considered emission-related components for evaporative
emissions:
•
•
•
•
•
•
•
•
•
Fuel Tank
Fuel Cap
Fuel Line
Fuel Line Fittings
Clamps*
Pressure Relief Valves*
Control Valves*
Control Solenoids*
Electronic Controls*
•
•
•
•
•
•
•
•
•
Vacuum Control Diagrams*
Control Cables*
Control Linkages*
Purge Valves
Vapor Hoses
Liquid/Vapor Separator
Carbon Canister
Canister Mounting Brackets
Carburetor Purge Port Connector
*As related to the evaporative emission control system.
If any emissions related component on your engine is defective, HAMMERHEAD will
repair or replace the defective component without charge for diagnosis, parts, or labor.
All defective parts replaced under this warranty become the property of
HAMMERHEAD.
92
WARRANTY
Emissions Control System Limited Warranty
EXCLUSIONS
This limited warranty excludes failures not caused by a defect in material or
workmanship. This limited warranty does not cover emissions control systems or parts
that are affected or damaged by owner abuse, neglect, improper maintenance, misuse,
improper fueling, improper storage, collision, accidents, or improper handling. This
limited warranty also does not cover any engine that has been structurally altered, or an
engine that has been used in racing competition. This limited warranty also does not
cover physical damage, corrosion or defects caused by fire, explosions or other similar
causes beyond the control of HAMMERHEAD, or by acts of God.
TO OBTAIN WARRANTY SERVICE
The vehicle owner must, at their own expense, take the small off-road engine, or the
product on which it is installed, along with the sales registration card or other proof of
original purchase date, to any qualified repair shop or qualified person. A qualified party
may maintain, replace, or repair the emission control devices or systems on your
vehicle. An authorized HAMMERHEAD dealer can perform any service that may be
necessary for your vehicle. HAMMERHEAD and authorized HAMMERHEAD dealers
can provide warranty replacement parts but equivalent parts can be used for emissionsrelated repairs. It is a potential violation of the Clean Air Act if a part supplied by an
aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission
controls. Tampering with emission controls is prohibited by federal law.
To receive information about how to make a warranty claim, how to make arrangements
for authorized repairs, or if you are unable to obtain emission warranty service or are
dissatisfied with warranty service received, please contact HAMMERHEAD for
additional assistance.
Hammerhead Off-Road Inc.
1200 Lakeside Parkway #400
Flower Mound, TX 75028
Telephone: 214-513-1700
RUWROOIUHHDW
Fax: 214-513-1711
Email: [email protected]
93
WARRANTY
DISCLAIMER
The exclusive remedy for breach of this limited warranty shall be, at the exclusive
option of HAMMERHEAD, repair or replacement of any defective materials,
components or products. THE REMEDIES SET FORTH IN THIS LIMITED
WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR
BREACH OF THIS WARRANTY. HAMMERHEAD SHALL HAVE NO LIABILITY
TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL
DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR
IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER
TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL,
INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL
SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS
ESSENTIAL PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. HAMMERHEAD DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply
if it is inconsistent with the controlling state law.
94
WARRANTY
Off-Road Warranty Registration Form
Registration Terms & Conditions
In order to activate the warranty, please follow the instructions below:
1. Make a copy of the Bill of Sale.
2. Make a copy of Pre-Delivery Checklist.
3. Fill out warranty card and send with all above documents to:
Hammerhead Off-Road
Attn: Warranty Registration
1200 Lakeside Parkway Ste. 400
Flower Mound, TX 75028
Or, Fax to 214-513-1738
Or, go online to www.hammerheadoffroad.com
under dealer’s only section
Hammerhead Off-Road Warranty Registration Card
(Must be sent in with a copy of sales receipt)
VIN# _______________________________ Model:______________
Dealer Name: ____________________________________________
Dealer Address: __________________________________________
City: _______________________ State: _______ Zip: ____________
Customer Name: _________________________________________
Customer City: _________________________ State: _____________
Customer Phone: ______________ Email: _____________________
Date of Purchase: _________________________________________
I Certify that all information provided is true and correct to the best of
my knowledge. I understand the exceptions and limitations of the
warranty coverage.
Customer Signature: _____________________ Date: ____________
95
MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE
96
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
97
INDEX
A
Adjustment
Steering Wheel. . . . . . . . . . . . .
Adjustment, Throttle Freeplay. . . . .
Air Filter . . . . . . . . . . . . . . . . . . . . .
Air Filter Cleaning. . . . . . . . . . . . . .
D
21
60
58
58
B
Battery . . . . . . . . . . . . . . . . . . . . 69-72
Charging (Sealed Battery) . . 71-72
Battery Installation. . . . . . . . . . . . . . 70
Battery Removal . . . . . . . . . . . . . . . 70
Battery Storage . . . . . . . . . . . . . . . . 71
Before Riding. . . . . . . . . . . . . . . . . . 28
Belt Burning. . . . . . . . . . . . . . . . . . . 83
Belt Wear . . . . . . . . . . . . . . . . . . . . . 83
Belts, Seat . . . . . . . . . . . . . . . . . . . . 21
Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Adjustment, Parking . . . . . . . 53
Brake Adjustment, Parking Brake Cable
Freeplay . . . . . . . . . . . . . . . . . . . . . . 53
Brake Fluid . . . . . . . . . . . . . . . . . . . 62
Brake Inspection . . . . . . . . . . . . . . . 61
Brake Pedal . . . . . . . . . . . . . . . . . . . 25
Brake System Break-in . . . . . . . . . . 27
Brakes . . . . . . . . . . . . . . . . . . . . . 61-62
Braking . . . . . . . . . . . . . . . . . . . . . . 31
Break-In Period . . . . . . . . . . . . . . 26-27
Burning Belts . . . . . . . . . . . . . . . . . . 83
C
Cap, Fuel . . . . . . . . . . . . . . . . . . . . . 25
Carburetor Jetting . . . . . . . . . . . . . . 82
Chart, Periodic Maintenance . . . . 41-45
Chrome Wheel Care . . . . . . . . . . . . 75
Cleaning and Storage. . . . . . . . . . 73-78
Cleaning the Air Filter . . . . . . . . . . . 58
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9
Component Locations . . . . . . . . . . . 20
Condition, Spark Plugs . . . . . . . . . . 54
CVT System. . . . . . . . . . . . . . . . . . . 57
Corrosion Removal, Chrome . . . . . . 75
Cover for Storage. . . . . . . . . . . . . . . 77
Crankcase Emission Control System 40
CVT Break-In . . . . . . . . . . . . . . . . . 27
CVT Drying . . . . . . . . . . . . . . . . . . . 57
CVT System. . . . . . . . . . . . . . . . . . . 57
98
Drive Belt Wear. . . . . . . . . . . . . . . . . 83
Drive Chain Lubrication . . . . . . . . . . 52
Drive Chain Slack Adjustment . . . . . 52
Drivetrain Break-In . . . . . . . . . . . . . . 27
Driving Downhill. . . . . . . . . . . . . . . . 37
Driving in Reverse. . . . . . . . . . . . . . . 38
Driving on a Sidehill . . . . . . . . . . . . . 37
Driving on Slippery Surfaces . . . . . . 35
Driving Over Obstacles . . . . . . . . . . . 39
Driving Procedures . . . . . . . . . . . 32-33
Driving Through Water . . . . . . . . . . . 38
Driving Uphill . . . . . . . . . . . . . . . . . . 36
Driving with a Passenger. . . . . . . . . . 34
E
Emission Control, Crankcase . . . . . . 40
Emission Control, Noise . . . . . . . . . . 40
Engine Break-In. . . . . . . . . . . . . . . . . 27
Engine Fogging . . . . . . . . . . . . . . . . . 77
Engine Oil . . . . . . . . . . . . . . . . . . 47-48
Engine Stopping . . . . . . . . . . . . . . . . 31
Equipment Modifications . . . . . . . . . . 7
Eye Protection . . . . . . . . . . . . . . . . . . . 9
F
Filter Care During Storage . . . . . . . . 76
Filter Cleaning, Air . . . . . . . . . . . . . . 58
Filter Systems . . . . . . . . . . . . . . . . . . 58
Filter, Air . . . . . . . . . . . . . . . . . . . . . . 58
Fluid
Main Gearcase . . . . . . . . . . . . . . 51
Transmission . . . . . . . . . . . . . . . 51
Fluid Change
Main Gearcase . . . . . . . . . . . . . . 51
Transmission . . . . . . . . . . . . . . . 51
Fluid Check
Main Gearcase . . . . . . . . . . . . . . 51
Transmission . . . . . . . . . . . . . . . 51
Fluid Levels During Storage . . . . . . . 76
Fluid, Brake . . . . . . . . . . . . . . . . . . . . 62
Fogging the Engine . . . . . . . . . . . . . . 77
Fouled Plugs . . . . . . . . . . . . . . . . . . . 54
Freeplay Adjustment, Throttle. . . . . . 60
Freeplay, Steering Wheel . . . . . . . . . 63
Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . 25
Fuel Safety. . . . . . . . . . . . . . . . . . . . . 17
Fuel Stabilizer . . . . . . . . . . . . . . . . . . 76
Fuel Tank Filler Cap . . . . . . . . . . . . . 25
INDEX
G
O
Gap, Spark Plug . . . . . . . . . . . . . . . . 54
Gasoline Handling . . . . . . . . . . . . . . 17
Gearcase Oil
Main . . . . . . . . . . . . . . . . . . . . . 51
Gearcases
Main Gearcase . . . . . . . . . . . . . 51
Transmission . . . . . . . . . . . . . . . 51
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9
Obstacles. . . . . . . . . . . . . . . . . . . . . . 39
Oil
Engine . . . . . . . . . . . . . . . . . 47-48
Main Gearcase . . . . . . . . . . . . . 51
Transmission. . . . . . . . . . . . . . . 51
Oil Change
Engine Oil . . . . . . . . . . . . . . 48-50
Main Gearcase . . . . . . . . . . . . . 51
Transmission. . . . . . . . . . . . . . . 51
Oil Check
Engine Oil . . . . . . . . . . . . . . . . . 47
Main Gearcase . . . . . . . . . . . . . 51
Transmission. . . . . . . . . . . . . . . 51
H
Helmet. . . . . . . . . . . . . . . . . . . . . . . . . 9
I
Ignition Switch . . . . . . . . . . . . . . . . .
Inspection, Brakes. . . . . . . . . . . . . . .
Inspection, Pre-Ride . . . . . . . . . . . . .
Inspection, Steering Wheel . . . . . . . .
Inspection, Throttle Freeplay . . . . . .
Installation, Battery. . . . . . . . . . . . . .
22
61
28
63
59
70
K
Key, Periodic Maintenance Chart . . . 42
L
Lamp Replacement
Tail Light . . . . . . . . . . . . . . . . . 67
Lamp Replacement, Daytime Running
Lights . . . . . . . . . . . . . . . . . . . . . . . . 67
Lights . . . . . . . . . . . . . . . . . . . . . . . . 67
Lubrication for Storage . . . . . . . . . . . 77
Lubrication Recommendations . . . . . 46
M
Maintenance Log . . . . . . . . . . . . . . . 96
Maintenance, Periodic . . . . . . . . 41-45
N
P
Parking Brake Adjustment . . . . . . . . 53
Parking Brake Cable Freeplay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 53
Parking on an Incline . . . . . . . . . . . . 38
Parking the Vehicle. . . . . . . . . . . . . . 31
Periodic Maintenance Chart . . . . 41-45
Plug Condition . . . . . . . . . . . . . . . . . 54
Plug Gap . . . . . . . . . . . . . . . . . . . . . . 54
Plug Torque . . . . . . . . . . . . . . . . . . . 54
Plug, Spark . . . . . . . . . . . . . . . . . . . . 54
Plugs, Fouled . . . . . . . . . . . . . . . . . . 54
Polishing the Vehicle . . . . . . . . . . . . 74
Pre-Ride Inspection . . . . . . . . . . . . . 28
R
Refueling Safety . . . . . . . . . . . . . . . . 17
Registration, Warranty . . . . . . . . . . . 87
Removal, Battery . . . . . . . . . . . . . . . 70
Removing the Vehicle from Storage 78
Reverse . . . . . . . . . . . . . . . . . . . . . . . 38
Riding Gear. . . . . . . . . . . . . . . . . . . 8-9
New Operator Procedures . . . . . . 32-33
Noise Emission Control System . . . . 40
99
INDEX
S
Safe Operation Practices . . . . . . . . . 29
Safety Labels . . . . . . . . . . . . . . . . 18-19
Safety Symbols . . . . . . . . . . . . . . . . . 4
Safety Training, ROHVA . . . . . 29, 32
Safety Warnings. . . . . . . . . . . . . 10-17
Age Restrictions . . . . . . . . . . . 10
Carrying a Passenger . . . . . . . . 12
Crossing Hillsides . . . . . . . . . . 13
Driving Downhill Improperly . 14
Excessive Speeds . . . . . . . . . . . 13
Exposure to Exhaust . . . . . . . . 17
Failure to Inspect . . . . . . . . . . . 11
Frozen Bodies of Water . . . . . . 16
Hot Exhaust Systems . . . . . . . . 17
Improper Hill Climbing . . . . . . 14
Improper Tires and Maintenance. .
16
Instruction . . . . . . . . . . . . . . . . 10
Jumps and Stunts . . . . . . . . . . . 13
Multiple Passengers . . . . . . . . . 12
Obstacles . . . . . . . . . . . . . . . . . 16
Operating a Damaged Vehicle. 17
Operating on Sand . . . . . . . . . . 15
Operating Through Water . . . . 16
Overloading . . . . . . . . . . . . . . . 15
Pavement . . . . . . . . . . . . . . . . . 12
Physical Control . . . . . . . . . . . 13
Protective Apparel . . . . . . . . . . 12
Public Roads . . . . . . . . . . . . . . 12
Reverse . . . . . . . . . . . . . . . . . . 15
Rider Height . . . . . . . . . . . . . . 11
Seat Belts . . . . . . . . . . . . . . . . . 11
Slippery Terrain . . . . . . . . . . . . 15
Stalling on a Hill . . . . . . . . . . . 14
Turning Improperly . . . . . . . . . 13
Unauthorized Use of the Vehicle. .
17
Unfamiliar Terrain . . . . . . . . . . 15
Using Alcohol or Drugs. . . . . . 11
Seat Belts . . . . . . . . . . . . . . . . . . . . . 21
Severe Use Definition . . . . . . . . . . . 41
Shock Spring Adjustment . . . . . . . . 63
Signal Words . . . . . . . . . . . . . . . . . . . 4
Spark Plug . . . . . . . . . . . . . . . . . . . . 54
Spark Plug Condition. . . . . . . . . . . . 54
Spark Plug Gap . . . . . . . . . . . . . . . . 54
Spark Plug Removal . . . . . . . . . . . . 55
Spark Plug Torque . . . . . . . . . . . . . . 54
Spark Plugs, Fouled . . . . . . . . . . . . . 54
Speed Control System . . . . . . . . . . . 25
Stabilizing the Fuel . . . . . . . . . . . . . 76
Steering Wheel Adjustment. . . . . . . 21
Steering Wheel Inspection. . . . . . . . 63
100
Stopping the Engine. . . . . . . . . . . . . . 31
Storage . . . . . . . . . . . . . . . . . . . . . 73-78
Storage and Inspection. . . . . . . . . . . . 77
Storage and Lubrication. . . . . . . . . . . 77
Storage Area . . . . . . . . . . . . . . . . . . . 77
Storage, Battery . . . . . . . . . . . . . . . . . 71
Storage, Covers . . . . . . . . . . . . . . . . . 77
Storage, Fluid Levels. . . . . . . . . . . . . 76
Storage, Oil Change. . . . . . . . . . . . . . 76
Storage, Removal. . . . . . . . . . . . . . . . 78
Switches
Ignition . . . . . . . . . . . . . . . . . . . 22
T
Tail Light . . . . . . . . . . . . . . . . . . . . . . 67
Throttle Freeplay Adjustment . . . . . . 60
Throttle Freeplay Inspection . . . . . . . 59
Throttle Freeplay, Freeplay, Throttle 59
Throttle Pedal . . . . . . . . . . . . . . . . . . 25
Throttle System . . . . . . . . . . . . . . . . . 59
Tire Tread Depth . . . . . . . . . . . . . . . . 65
Tires . . . . . . . . . . . . . . . . . . . . . . 65-66
Front Wheel Hub Tightening. . . 65
Wheel Nut Torque . . . . . . . . . . . 66
Toe Alignment. . . . . . . . . . . . . . . . . . 64
Torque, Spark Plug . . . . . . . . . . . . . . 54
Transmission Oil . . . . . . . . . . . . . . . . 51
Transporting the Vehicle . . . . . . . . . . 78
Tread Depth, Tire . . . . . . . . . . . . . . . 65
V
Vehicle Identification Numbers. . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . . 68
Vehicle Transport . . . . . . . . . . . . . . . 78
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle . . . . . . . . . . 73-74
Water, Immersion of Vehicle . . . . . . 68
Wear, Drive Belt . . . . . . . . . . . . . . . . 83
Wheel Hub Tightening . . . . . . . . . . . 65
Wheel Nut Torque Specifications . . . 66
Wheel Replacement. . . . . . . . . . . 65-66
Wheels, Front. . . . . . . . . . . . . . . . . . . 65
Wheels, Rear . . . . . . . . . . . . . . . . . . . 66
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER Operate:
• If you are under age 16 and without a valid driver’s license.
• Without first viewing safety video and taking a ROHVA training course at
www.rohva.org.
• On excessively steep hills.
• On public roads (unless designated for off-road use).
• With a passenger who is not seated in a passenger seat, or with passengers
under age 12 or who cannot comfortably reach the floor and hand holds.
• On paved surfaces - pavement may seriously affect handling and control.
• With non-Polaris approved accessories - they may seriously affect stability.
ALWAYS:
• Wear your seat belt. Vehicle rollover can cause severe injury or death.
• Secure cab nets or doors and keep hands and feet inside vehicle at all times.
• Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and
over-the-ankle boots.
• Reduce speed and use extra caution when carrying passengers.
• Avoid sharp turns or turns while applying heavy throttle.
• Operate slowly in reverse - avoid sharp turns or sudden braking.
• Make sure passengers read and understand all safety labels.
ALL RIDERS MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR.
ALL RIDERS MUST WEAR SEAT BELTS. NEVER USE ON PUBLIC ROADS.
NEVER USE WITH DRUGS OR ALCOHOL.
READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
Hammerhead Off-Road is part of the
Polaris Family.
Polaris Industries Inc.
2100 Highway 55
Medina, MN 55340
Part No. 9927515 Rev 02
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