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Polaris Hawkeye User Manual
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3.9
ENGINE
OIL FLOW DIAGRAM
Camshaft
S
procket & Chain
Chain Room
Oil Pressure Inspection
Oil Cooler / Filter
Oil Pump
Crankshaf
t
PTO SIDE
MAG SIDE
Engine Sump
Oil Pickup
Screen
Crankca
se
Oil Passage
Crankcase
Oil Passage
S
t
ator Plate
Counter Bala
nce Gear
Connecting Rod Big End
Connecting Rod Small End
Piston Skirt / Rings
Main B
earing
Right Rear
Cylinder Bo
lt
Cylinder He
ad
OIL FLOW DIAGRAM KEY
Indirect
Direct
Rocker Arm
Rocker Shaft
Va
l
v
e
S
p
r
i
n
g
s
S
t
arting Clutch
Crankcase
Oil Passage
(RH Cam Journal
)
Crankcase
Oil Passage
& Accy Oil Cooler
Fitting Location
ES300PFE010
Main Bearing
S
t
arting Cl
utch
One W
ay Clutch
Nozzle
46
48
Table of Contents
General Information
1
Table of Contents
1
Chapter 1
2
Engine Designation Number
2
Model Identification
2
Vehicle and Engine Serial Number Locations
2
Vehicle Identification
2
Vehicle Identification Number (Vin)
2
Specifications
3
Model:2006 Hawkeye 2X4
3
Model:2006 Hawkeye 2X4
4
Model:2006 Hawkeye 4X4
6
General Information
6
Publication Numbers
6
Replacement Keys
6
Special Tools
7
Standard Torque Specifications
9
Sae Tap Drill Sizes
10
Metric Tap Drill Sizes
10
Decimal Equivalents
10
Conversion Table
11
Glossary of Terms
12
- Www.instant-Manuals.com - Maintenance Chapter 2 Maintenance
13
Chapter 2
14
Maintenance
14
Maintenance Chart Key
14
Periodic Maintenance Chart
14
Maintenance and Lubrication
15
Lubricants / Fluids
18
Polaris Lubes/Fluids
18
Polaris Lubricants,Maintenance and Service Products
19
Polaris Lubricant Symbol Identification
20
Vehicle Inspection / Maintenance
20
Pre-Ride / Daily Inspection
20
Hawkeye Handlebar Component Locations
21
Maintenance Quick Reference
21
Transmission Lubrication
23
Front Gearcase Lubrication (4X4 Only)
23
Lubrication / Grease Points
24
Throttle Operation - All Models
24
Choke (Enricher) Adjustment
24
Carburetor Draining
24
Pilot Screw
25
Pilot Screw Adjustment
25
Electronic Throttle Control (Etc Switch)/Throttle Cable Adjustment
26
Fuel System
26
Fuel Lines
26
Vent Lines
26
Fuel Filter
26
Compression Test
27
Engine Mounts
27
Engine Fastener Torque
27
Battery Maintenance
27
Spark Plug
28
Ignition Timing
29
Main Air Filter Cleaning
29
Air Filter/Pre-Filter Service
29
Air Box Sediment Tube
30
Cvt Drain Plug & Drying
30
Engine Oil Level
30
Oil and Filter Change
31
Valve Clearance Adjustment
32
Steering
32
Tie Rod End/Steering Inspection
33
Camber and Caster
33
Toe Alignment
33
Toe Alignment Adjustment
34
Exhaust Cleaning
34
Brake System Inspection
35
Brake Pad Inspection
35
Hose/Fitting Inspection
35
Brake Freeplay
35
Suspension Spring Front / Rear Preload Adjustment
36
Front Suspension Inspection
37
Rear Suspension Inspection
37
Controls
37
Wheels
37
Wheel, Hub, and Spindle
37
Torque Table2.25
37
Wheel Removal/Install- Front or Rear
37
Wheel Installation
38
Tire Pressure
38
Tire Inspection
38
Frame, Nuts, Bolts, Fasteners
38
- Www.instant-Manuals.com - Chapter 3 Engine
39
Chapter 3 Engine
41
Special Tools
41
Tools
41
Torque Specifications
41
Engine Torque Specifications
41
Torque Patterns
42
General Engine Service
43
Engine Exploded View
43
Engine Service Data
44
Oil Flow Diagram
47
Piston Identification
48
Piston Ring Identification
48
Accessible Components
48
Engine Service
48
Engine Removal
48
Engine Installation Notes
51
Transmission Removal
52
Transmission Installation Notes
53
Engine Lubrication
54
Oil Flow / Pressure Test
54
Engine Breather / Oil Separator
54
Cam Chain Tensioner Removal
54
Cam Chain Tensioner Inspection
55
Rocker Arm/Shaft Disassembly and Inspection
55
Camshaft Removal and Inspection
56
Camshaft Inspection
57
Cylinder Head Removal
57
Cylinder Head Inspection
57
Cylinder Head Warp Inspection
58
Combustion Chamber Inspection
58
Cylinder Head Disassembly
58
Valve Inspection
59
Valve Seat Reconditioning
59
Cylinder Head Assembly
62
Valve Sealing Test
62
Engine Bottom End Disassembly
63
Cam Chain Guide and Tesioner Blade
63
Piston Removal
63
Cylinder Inspection
64
Cylinder Hone Selection/ Honing Procedure
64
Honing to Deglaze
64
Piston Inspection
65
Piston Ring Installed Gap
66
Flywheel Removal / Inspection
66
Starter Drive Clutch Removal/Inspection
67
Cam Chain Drive Sprocket Removal / Inspection
67
Oil Pump Inspection / Removal
68
Starting Clutch and Engine Braking Clutch Removal /Inspection
68
Starting Clutch Assembly
69
Crankcase Disassembly
70
Crankcase Separation
70
Crankshaft Removal
71
Crankshaft / Cam Chain / Sprocket Inspection
71
Crankcase Oil Passages & Pressure Relief Valve
72
Balance Shaft Bearing Inspection
72
Bearing /Seal Installation
72
Camshaft Chain
72
Crankcase Oil Pickup Strainer Inspection
72
Crankshaft End Play Adjustment
73
End Play Inspection/Adjustment
73
Counter Balancer Shaft End Play Adjust
74
Crankcase Reassembly
75
Cam Chain, Oil Pump, & Tensioner Blade Installation
76
Piston Installation
77
Piston Ring Installation
77
Cylinder Head and Camshaft Installation
78
Cylinder Installation
78
Camshaft Installation & Timing
79
Cam Chain Tensioner Installation
80
Rocker Arm Installation
80
Spark Plug Fouling Troubleshooting
81
Starter Drive Assembly
81
Troubleshooting
81
Engine Troubleshooting
82
- Www.instant-Manuals.com - Fuel System / Carburetion Chapter 4 Fuel System / Carburetion
85
Special Tools
86
Bst 34 Carburetor Exploded View 1 of 2
87
Carburetition
87
Chapter 4
87
Bst 34 Carburetor Exploded View 2 of 2
88
Carburetor Venting System
89
Carburetor Jetting
90
Carburetor Specifications
90
CV Carburetor System Function
90
Mikuni Jet Part Numbers
90
Carburetor Venting
91
Mikuni CV Carb Operation
91
Pilot (Idle and Slow) System
92
Starter System (Choke or Enrichment)
92
Float System
93
Main System
93
Air/Fuel Mixture Ratio
94
Pilot Screw
94
Jet Needle
95
Needle Jet
95
Throttle Opening Vs. Fuel Flow
95
Carburetor Disassembly - Mikuni CV
96
Carburetor Cleaning
97
Carburetor Inspection
97
Carburetor Assembly
98
Float Height Adjustment
98
Fuel Level Test
99
Needle and Seat Leakage Test
99
Troubleshooting
100
Air Intake System
101
Fuel Tank/Fuel Delivery System
102
Exhaust System
103
- Www.instant-Manuals.com - Body and Steering Chapter 5 Body and Steering
105
Chapter 5 Removal / Installation
106
Plastic Insert
106
Seat
106
Seat Removal/Installation
106
Front Cab/Fender
107
Front Cab/Fender Removal
108
Front Cab/Fender Instalation
108
Body Assembly
109
Exploded View
109
Rear Cab Removal/Installation
109
Footwell Removal/Installation
109
Body Rack Exploded View
110
Rear Rack Removal/Installation
110
Pod Exploded View
111
Pod/Key Switch/Choke/Speedo Connection Removal/Installation
112
Steering
112
Handlebar Removal
112
Handlebar Installation
113
Steering Post Removal
114
Steering Post Bearing Replacement
115
Steering Post Installation
115
Steering / A-Arm
116
Exploded View
116
A-Arm
117
A-Arm Removal
117
A-Arm Assembly
117
Front Strut Cartridge Replacement
117
Front Strut Removal
118
Front Strut Installation
118
Bearing Replacement
118
Ball Joint
119
Replacement
119
Rear Suspension
119
Upper and Lower Rear Control Arm Removal/Installation
120
- Www.instant-Manuals.com - Brakes Chapter 6 Brakes
125
Chapter 6 Brakes / Torque
126
Specifications
126
Troubleshooting
127
Brake Noise
127
Brake System Main Components
128
Brake Caliper
129
Exploded View
129
Hydraulic Brake System
129
Operation Overview
130
Brake Bleeding
131
Fluid Change
131
Brake Bleeding
132
Rear Master Cylinder
131
Operation Overview
131
Hand Brake Master Cylinder
133
Removal
133
Installation
134
Brake Pads
135
Removal
135
Installation
136
Front Caliper
136
Removal
136
Inspection
138
Reassembly
139
Installation
139
Brake Burnishing Procedure
140
Overview
140
Brake Disc
140
Thickness / Runout Inspection
140
Wear Inspection
140
Removal / Replacement
141
Foot Brake
141
Foot Pedal Removal / Install
141
Foot Brake Master Cylinder Removal / Installation
142
Troubleshooting
142
- Www.instant-Manuals.com - Final Drive Chapter 7 Final Drive
143
Chapter 7 Component Torques
144
Front Drive CV Shaft
144
Removal
144
Installation
145
Specifications
144
CV Boot Service
145
Inspection
145
Disassembly
145
Front Hub Bearing (2X4/4X4)
147
Removal
147
Installation
147
Front Prop Shaft
147
U-Joint Service
148
Disassembly
148
Assembly
149
Awd Front Drive Axle Exploded View
150
Front Drive Shafts and Propshafts
150
Front Gearcase - Centralized Hilliard
151
Operation Overview
151
Front Gearcase
152
Centralized Hilliard Exploded View
152
All Wheel Drive Gearcase
153
Removal
153
Disassembly
154
Reassembly
157
Awd Diagnostics: Awd will Not Engage
159
Installation
160
Rear Hub
161
Removal
161
Disassembly
162
Rear Hub Assembly
163
Installation
163
Drive Shaft and CV Joint
164
Handling Tips
164
Rear CV Shaft
164
Removal
164
Rear CV Shaft
165
Installation
165
CV Joint Service
166
CV Joint Replacement
166
Removal and Cleaning
167
- Www.instant-Manuals.com - Cvt Transmission Chapter 8 Cvt / Transmission
169
Chapter 8 Cvt Torque Specifications
170
Torque Specifications
170
Gear Selection
171
Shift Linkage Inspection
171
Gear Selector Removal
171
Special Tools
171
Cvt Operation
172
Cvt Operation Overview
172
Starting Clutch Operation
172
Drive Clutch Operation
172
Driven Clutch Operation
172
Engine Braking Clutch
173
Cvt Maintenance/Inspection
173
Cvt Drying
173
Cvt Overheating/Diagnosis
174
Cvt System Disassembly / Drive Clutch
176
Cvt System / Driven Clutch Service
178
Transmission
181
Transmission Service
182
Transmission Disassembly
182
- Www.instant-Manuals.com - Electrical Chapter 9 Electrical
187
Chapter 9 Electrical
188
Electrical
188
Electrical Service Notes
188
Electrical System
188
Fuse Splice Saver
188
Fusible Link
188
Special Tools
188
Gear Position Switch
189
Rpm Limit Modes
189
Instrument Gauge Power / Fwd / Neutral Switches / Rpm Signal
190
Vehicle Speed Sensor
191
Awd Control System
192
Etc / Reverse Rpm Control System
193
Charging System
194
Ignition System
195
Starting System
196
Ignition Coil Testing
197
Stator Function Test
197
CDI Cranking Output Test
198
CDI Output Test Using Peak Reading Adaptor or Avoltmeter
198
Electronic Throttle Control (Etc) Switch
199
Ignition System Testing
199
Ignition System Troubleshooting
200
Charging System Testing
202
Charging System "Break Even" Test
203
Current Draw - Key off
203
Alternator Output Test (Ac Amp)
204
Battery Identification
204
Battery Terminals/Terminal Bolts
205
Conventional Battery Activation/ Svc
205
Conventional Battery Inspection/Removal
206
Conventional Battery Installation
206
Conventional Battery Ocv - Open Circuit Voltage Test
206
Conventional Battery Testing
206
Conventional Battery Load Test
207
Conventional Battery Specific Gravity Test
207
Conventional Battery Charging Procedure
208
Conventional Battery Off-Season Storage
208
Starter System Testing Flow Chart
209
Starter Motor Exploded View
210
Starter Motor
211
Removal / Disassembly
211
Starter System
211
Troubleshooting
211
Voltage Drop
211
Testing
211
Brushes
212
Inspection & Replacement
212
Armature
213
Testing
213
Starter
213
Reassembly & Installation
213
Starter Solenoid
214
Bench Testing
214
Starter Drive
215
Pinion Gear - Anti-Kick out Shoe, Garter Spring Replacement
215
4
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Polaris Hawkeye Specifications
General
Brand
Polaris
Model
Hawkeye
Category
Offroad Vehicle
Language
English
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