Hammerhead Off-Road GTS 150 User manual

®

POLARIS® and HAMMERHEAD® are trademarks of POLARIS Industries
Inc.
Copyright 2018 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 China
9929665

Introduction . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . 9
Features and Controls . . . . . . . . . . . . . . 23
Operation . . . . . . . . . . . . . . . . . . . . 31
Emission Control Systems . . . . . . . . . . . . . 43
Maintenance . . . . . . . . . . . . . . . . . . 45
Specifications . . . . . . . . . . . . . . . . . . 81
Troubleshooting . . . . . . . . . . . . . . . . . 87
Warranty . . . . . . . . . . . . . . . . . . . . 91
Maintenance Log . . . . . . . . . . . . . . . . 101
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4

INTRODUCTION
SAFETY SYMBOLS AND SIGNAL WORDS
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.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in
death or serious injury.
WARNING
SAFETY ALERT WARNING indicates a hazardous situation which, if not
avoided, COULD result in serious injury.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not
avoided, COULD result in minor to moderate injury.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle
damage or property damage.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and
inspection of components.
NOTICE
NOTICE provides key information by clarifying instructions.
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.
5
INTRODUCTION

HAMMERHEAD WARNING
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 visibility.
• Never use this vehicle with drugs or alcohol, as these conditions impair
judgment and reduce operator reaction time.
• Complete the steps outlined in the New Operator Driving Procedures
section. Never allow a guest to operate this vehicle until the guest has
watched the instructional video and has completed the New Operator
Driving Procedures.
6
INTRODUCTION

VEHICLE IDENTIFICATION NUMBERS
Record your vehicle's identification numbers in the spaces provided. Remove
the spare key and store it in a safe place.
q Vehicle Identification Number (GTS/Platinum-on frame behind driver
seat, LE-under right rear fender near top of shock)
w Engine Serial Number (on engine case and air filter)
e Manufacturing Data Label (on driver side floorboard)
r LE-Model Vehicle Identification Number (passenger side under
fender)
Vehicle Model Number:
Vehicle Identification Number (VIN):
Engine Serial Number:
Key Number:
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INTRODUCTION

8

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.
9
SAFETY

SAFE RIDING GEAR
Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-
the-ankle boots and seat belt (if equipped) at all times. Protective gear reduces
the chance of injury.
RIDER COMFORT
Under certain operating conditions, heat generated by the engine and exhaust
system can elevate temperatures in the rider 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.
qHelmet
wEye Protection
eLong Sleeves
rGloves
tLong Pants
yOver-the-Ankle Boots
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SAFETY

CLOTHING
Wear long sleeves and long pants to protect arms and legs.
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. Clasp the buckle and pull each strap tight to
ensure the helmet is properly secured to the head.
Parents should verify that young operators have a helmet that fits, and should
obtain one of proper size if it does not fit before allowing operation.
Approved helmets in the USA and Canada bear a U.S.
Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear
the ECE 22.05 label. The ECE mark consists of a
circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the 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.
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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 and in the safety DVD
provided with your vehicle.
Be sure to read all of the following warnings about driving hazards and how to
avoid them. These warnings are provided for your child's safety. Be sure to
explain to your young driver that 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.
FOR MORE INFORMATION ABOUT SAFETYcall POLARIS at 1–800–342–
3764.
OPERATING WITHOUT INSTRUCTION
Operating this vehicle without proper instruction
increases the risk of an accident. The operator and the
supervising adult must understand how to operate the
vehicle properly in different situations and on different
types of terrain.
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.
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.
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SAFETY

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
overhead cab frame is less than 2 inches (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
Operating 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 this vehicle.
FAILURE TO INSPECT BEFORE OPERATING
WARNING
Failure to inspect and verify that the vehicle is in safe
operating condition before operating increases the risk
of an accident.
Always perform the pre-ride inspection before each
use of your vehicle to make sure it's in safe operating
condition.
Always follow the inspection and maintenance
procedures and schedules described in this manual.
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SAFETY

PROTECTIVE APPAREL
Riding in this vehicle without wearing an approved
helmet and protective eye wear increases the risk of a
serious injuries 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 steps in the New Operator Driving Procedures.
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. If it's unavoidable, travel slowly, travel short distances and
avoid sudden turns or stops.
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).
14
SAFETY

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 and your 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.
Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. 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.
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.
15
SAFETY

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.
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. 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.
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.
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SAFETY

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.
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 with this vehicle.
• Never exceed the maximum weight capacity for this vehicle.
OPERATING OVER OBSTACLES
Improperly operating over obstacles could cause loss
of control or rollover.
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as large
rocks and fallen trees. Always follow the proper
procedures outlined in this manual when operating
over obstacles.
17
SAFETY

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.
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.
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.
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SAFETY

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.
• Never carry fuel or other flammable liquids on this vehicle. Failure to follow
this instruction could lead to serious injury or death.
• 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
WARNING
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 or without proper training. This could result in an
accident or rollover. Always remove the ignition key when the vehicle is not in
use.
19
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 go-kart 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 go-kart.
• Never operate this go-kart without proper instructions. Beginners require
adult supervision.
• Never operate this go-kart 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 go-kart at excessive speeds. You increase your risk of
los-ing 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.
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SAFETY