Polaris Hawkeye User Manual

1.1
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . .1.2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL:2006 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
MODEL: 2006 HAWKEYE 4X4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL:2006 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4
MODEL:2006 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

Polaris Hawkeye Specifications

General

Brand	Polaris
Model	Hawkeye
Category	Offroad Vehicle
Language	English

Summary

General Information

Vehicle Identification

Information on identifying the vehicle's model, engine, and serial numbers.

Engine

Torque Specifications

Provides torque values for engine components and fasteners.

General Engine Service

Exploded views, service data, and identification of engine components.

Engine Service

Detailed procedures for engine removal, installation, and component service.

Engine Lubrication

Fuel System / Carburetion

Carburettition

Exploded views, components, specifications, and operation of the carburetor.

Brakes

Troubleshooting

Brake System Main Components

Brake Caliper

Hydraulic Brake System

Overview of operation, master cylinder function, and brake bleeding procedures.

Rear Master Cylinder

Brake Bleeding

Step-by-step procedure for bleeding the hydraulic brake system.

Hand Brake Master Cylinder

Brake Pads

Front Caliper

Brake Disc

Foot Brake

Final Drive

Specifications

Component torque specifications and special tools for final drive service.

Front Drive CV Shaft

Procedures for removing, installing, and servicing the front drive CV shaft.

CV Boot Service

Front Hub Bearing (2x4/4x4)

Front Gearcase - Centralized Hilliard

Operation overview and engagement of the centralized Hilliard AWD system.

All Wheel Drive Gearcase

Procedures for removing, disassembling, and reassembling the AWD gearcase.

Rear Hub

Rear CV Shaft

CV Joint Service

CVT / Transmission

Torque Specifications

CVT Operation

CVT Maintenance/Inspection

CVT Overheating/Diagnosis

CVT System Disassembly / Drive Clutch

Steps for disassembling the CVT system and the drive clutch.

CVT System / Driven Clutch Service

Procedures for servicing the driven clutch assembly.

Transmission

Exploded view of the transmission and service overview.

Transmission Service

Procedures for draining fluid and removing the transmission.

Transmission Disassembly

Step-by-step instructions for disassembling the transmission.

Electrical

Electrical System

Charging System

Components and testing procedures for the charging system.

Ignition System

Components and testing procedures for the ignition system.

Starting System

Components and testing procedures for the starting system.

Ignition Coil Testing

Stator Function Test

CDI Output Test Using Peak Reading Adaptor or a Voltmeter

CDI Cranking Output Test

Ignition System Testing

Ignition System Troubleshooting

Diagnostic guide for common ignition system problems and no-spark conditions.

Charging System Testing

Step-by-step checks for diagnosing charging system problems.

Current Draw - Key Off

Charging System "Break Even" Test

Alternator Output Test (AC Amp)

Conventional Battery Testing

Starter System Testing Flow Chart

Diagnostic flowchart for troubleshooting starter motor issues.

Starter System

Troubleshooting guide for starter motor problems and voltage drop testing.

Starter Motor

Procedures for starter motor removal, disassembly, and testing.

Brushes

Armature

Starter

Reassembly and installation of the starter motor.

Starter Solenoid

Starter Drive