Polaris Hawkeye, 2006 HAWKEYE 2x4, 2006 Hawkeye 4x4 Repair Manual

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

1.1

GENERAL INFORMATION

VEHICLE IDENTIFICATION

Model Identification

The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

A 0 6 LB 2 7 A A

Year Designation

Basic Chassis

Designation

Engine Designation Number

ES30PFE ............................................................Single, Air Cooled, SOHC 4 Stroke, Electric Start

Vehicle Identification Number (VIN)

World

Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A P B 2 0 A * 5 P 0 0 0 0 0 0

Vehicle Descriptor

}

Vehicle Identifier

}

Emissions & Model Option

Engine Designation

}

Body Style

Vehicle and Engine Serial Number Locations

Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional num ber is stamped on the center top of crankcase beneath the cylinder coolant elbow.

The machine serial number (1- lower frame rail) and engine number (2- right side engine) are important for

vehicle identification.

Engine

Powertrain

Emissions

Model

Year

Check Digit

Plant No

Individual Serial Number

* This could be either

a number or a letter

1.2

SPECIFICATIONS

MODEL: 2006 HAWKEYE 2x4

MODEL NUMBER: . . . . . . . . .A06LB27AA

ENGINE MODEL: . . . . . . . . . .ES30PFE

Category Dimension

Length 74 in./188 cm Width 42 in./107 cm Height 45.5 in./116 cm Wheel Base 46 in./117 cm Ground Clearance 8 in./20.3 cm Dry Weight 525 lbs./238 kg Gross Vehicle Weight 930 lbs./422 kg Front Rack Capacity 70 lbs./31.75 kg Rear Rack Capacity 100 lbs./45 kg Towing Capacity 750 lbs./340 kg Hitch Tongue Weight 75 lbs./34 kg Body Style Recreational/Utility

GENERAL INFORMATION

MODEL: . . . . . . . . . . . . 2006 HAWKEYE 4x4

MODEL NUMBER: . . . . . . . . .A06LD27AA

ENGINE MODEL: . . . . . . . . . .ES30PFE

Category Dimension

Length 74 in./188 cm Width 42 in./107 cm Height 45.5 in./116 cm Wheel Base 46 in./117 cm Ground Clearance 8 in./20.3 cm Dry Weight 550 lbs./250 kg Gross Vehicle Weight 930 lbs./422 kg Front Rack Capacity 70 lbs./31.75 kg Rear Rack Capacity 100 lbs./45 kg Towing Capacity 750 lbs./340 kg Hitch Tongue Weight 75 lbs./34 kg Body Style Recreational/Utility

1.3

GENERAL INFORMATION

MODEL: 2006 HAWKEYE 2x4

MODEL NUMBER: A06LB27AA ENGINE MODEL: ES30PFE

Engine

Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES300PFE010 Engine Displacement 299cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm Compression Ratio 9.2:1 Full Stroke Compression Pressure Compression Relase 60-90 psi Engine Idle Speed Cooling System/Capacity Air/Oil Cooled Overheat Warning Lubrication Wet Sump Oil Requirements Polaris 0W-50 / 2 qts (1.9L) Exhaust System Single Pipe - USFS Approved

Carburetion

Carburetor model Mikuni BST 34mm Main Jet 147.5 Pilot Jet 42.5 Jet Needle 4HB42-5 Needle Jet 0-4m Pilot/Air Screw 2.5 Turns Out (Initial setting)

Float Height 13mm from carburetor body Fuel Delivery Fuel Pump Fuel Capacity /

Requirement

Electrical

Alternator Output 250 watt / 18.6 Amp @ 6000 Voltage Regulator 3-phase Lights : High Beam --

Low Beam 37.5 watts Brake 12V / 26.9 watts

Tail 12V / 8.26 watts Ignition System DC CDI Ignition Timing BTDC 30+/-2deg. @ 5000 RPM Spark plug / Gap NGK CR8E

Battery / Model / Amp Hr Conventional 14 Amp/hr Circuit Breakers

Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up Indicator Panel LCD / Indicator lights

1300 RPM

None

4.5 gal. (17 L)

87 Octane (minimum)

89 Oxygenated

.031 in. / .8 mm

Drivetrain

Transmission Type H-N-R Transmission Capacity 15.2 oz. (450 ml) Gear Ratio : Foward

Reverse

15.18:1

14.05:1 Clutch Type CVT w/EBS Belt 3211108

Steering / Suspension

Front Suspension / Shock Mac Pherson Strut Front Travel 7 in. / 17.8 cm Rear Suspension

Style / Shock

Independent

Coil-over Adjustable Rear Travel 8 in. / 20.3 cm Ground Clearance 8 in. / 20.3 cm Shock Preload Adjustment

Front / Rear

Front - Cam

Rear - Cam Turning Radius 62.5 in. (159 cm) unloaded Toe Out 0-1/16 in. (0-.159 mm)

Wheels / Brakes

Tire/Rim Size - Front 22 x 7-12 Tire/Rim Size - Rear 22 x 10-12 Air Press. F/R Tires 3-5 psi Brake - Front Single Control Hydraulic Disc Brake - Rear Single Control Hydraulic Disc Brake Fluid Polaris DOT 3 or 4 Brake Fluid

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40o F

Below 5

152.5 147.5

147.5 142.5

Above +40

Above +5

CLUTCH CHART

Altitude Shift Weight

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000 - 12000)

14 g (Yellow)

5412989

12 g (Red)

5412987

1.4

GENERAL INFORMATION

MODEL: 2006 HAWKEYE 4x4

MODEL NUMBER: A06LD27AA ENGINE MODEL: ES30PFE

Engine

Carburetion

Carburetor model Mikuni BST 34mm Main Jet 147.5 Pilot Jet 42.5 Jet Needle 4HB42-5 Needle Jet 0-4m Pilot/Air Screw 2.5 Turns Out (Initial setting)

Float Height 13mm from carburetor body Fuel Delivery Fuel Pump Fuel Capacity /

Requirement

Electrical

Alternator Output 250 watt / 18.6 Amp @ 6000 Voltage Regulator 3-phase Lights : High Beam --

Low Beam 37.5 watts Brake 12V / 26.9 watts

Tail 12V / 8.26 watts Ignition System DC CDI Ignition Timing BTDC 30+/-2deg. @ 5000 RPM Spark plug / Gap NGK CR8E

Battery / Model / Amp Hr Conventional 14 Amp/hr Circuit Breakers

Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up Indicator Panel LCD / Indicator lights

1300 RPM

None

4.5 gal. (17 L)

87 Octane (minimum)

89 Oxygenated

.031 in. / .8 mm

Drivetrain

Transmission Type H-N-R Transmission Capacity 15.2 oz. (450 ml) Gear Ratio : Front Output

Rear Output

Fwd 5.17:1 / Rev 4.79:1

Fwd 15.18:1 / Rev 14.05:1 Clutch Type CVT w/EBS Belt 3211108

Steering / Suspension

Front Suspension / Shock Mac Pherson Strut Front Travel 7 in. / 17.8 cm Rear Suspension

Style / Shock

Independent

Coil-over Adjustable Rear Travel 8 in. / 20.3 cm Ground Clearance 8 in. / 20.3 cm Shock Preload Adjustment

Front / Rear

Front - Cam

Rear - Cam Turning Radius 62.5 in. (159 cm) unloaded Toe Out 0-1/16 in. (0-.159 mm)

Wheels / Brakes

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40o F

Below 5

152.5 147.5

147.5 142.5

Above +40

Above +5

CLUTCH CHART

Altitude Shift Weight

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000 - 12000)

14 g (Yellow)

5412989

12 g (Red)

5412987

1.5

GENERAL INFORMATION

PUBLICATION NUMBERS

Year Model Model No. Owner’s Manual PNParts Manual

2006 Hawkeye 2x4 A06LB27AA 9920202 9920207 9920208 2006 Hawkeye 4x4 A06LD27AB,AC 9920202 9920207 9920208

NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from

www.purepolaris.com.

Parts Micro

Fiche PN

REPLACEMENT KEYS

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary.

Series # Part Number

20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

1.6

GENERAL INFORMATION

SPECIAL TOOLS

Special Tools may be required while servicing your machine. Some of the tools listed are mandatory and other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris special tools when servicing any Polaris product.

Standard Tools and Engine Tools

2871293 - B - Crankshaft

Slotted Nut Socket

PA - 47344 - Balance Shaft

Slotted Nut Socket

Standard Tools and Engine Tools

2870569 - Crankshaft True Kit

PV - 35667 - A - Cylinder Leakdown Tester

PU - 45432 - Caliper or A Basic Caliper

2870975 - Mity Vac

2870773 - C - Clip Install Tool

2870390 - Piston Support Block

PA-47478 - Drive Clutch Holder

Suspension Tools

2870871 - ATV Ball Joint Tool Kit

2870623 - Shock Spring Compressor

1.7

GENERAL INFORMATION

Standard Tools and Engine Tools

2870303- Hone Kit

2870305 - Stone Replacement Kit

Electrical Tools

PV -43568 - FlukeTM 77 Multimeter

PV-39617 - Current Clamp

2870836 - Battery Hydrometer

2870588 - Hone Oil (12 OZ.)

2200634 - Valve Seat Reconditioning Kit

2870459 - Dial Indicator

8712500 - PV-39951-A

Tachometer Tachometer

1.8

GENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque in. lbs. (Nm)

#10 - 24 . . . . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . 43 (5.0) . . . . . . . . .60 (6.9)

#10 - 32 . . . . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . 49 (5.6) . . . . . . . . .68 (7.8)

Torque ft. lbs. (Nm)*

1/4 - 20 . . . . . . . . . . . . . . . . . 5 (7). . . . . . . . . . . . 8 (11). . . . . . . . . . .12 (16)

1/4 - 28 . . . . . . . . . . . . . . . . . 6 (8). . . . . . . . . . . . 10 (14) . . . . . . . . .14 (19)

5/16 - 18 . . . . . . . . . . . . . . . . . 11(15) . . . . . . . . . . 17 (23) . . . . . . . . .25 (35)

5/16 - 24 . . . . . . . . . . . . . . . . . 12(16) . . . . . . . . . . 19 (26) . . . . . . . . .29 (40)

3/8 - 16 . . . . . . . . . . . . . . . . . 20(27) . . . . . . . . . . 30 (40) . . . . . . . . .45 (62)

3/8 - 24 . . . . . . . . . . . . . . . . . 23(32) . . . . . . . . . . 35 (48) . . . . . . . . .50 (69)

7/16 - 14 . . . . . . . . . . . . . . . . . 30(40) . . . . . . . . . . 50 (69) . . . . . . . . .70 (97)

7/16 - 20 . . . . . . . . . . . . . . . . . 35(48) . . . . . . . . . . 55 (76) . . . . . . . . .80 (110)

1/2 - 13 . . . . . . . . . . . . . . . . . 50(69) . . . . . . . . . . 75 (104) . . . . . . . .110 (152)

1/2 - 20 . . . . . . . . . . . . . . . . . 55(76) . . . . . . . . . . 90 (124) . . . . . . . .120 (166)

Metric / Torque

6 x 1.0. . . . . . . . . . . 72-78 In.lbs.. . . . . . . . .8 x 1.25 14-18 ft.lbs. . . .10 x 1.25 26-30 ft.lbs.

1.9

GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size/ Drill Size Thread Size / Drill Size

#0-80 3/64 1/2-13 27/64 #1-64 53 1/2-20 29/64 #1-72 53 9/16-12 31/64 #2-56 51 9/16-18 33/64 #2-64 50 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 45 3/4-10 21/32 #4-40 43 3/4-16 11/16 #4-48 42 7/8-9 49/64 #5-40 38 7/8-14 13/16 #5-44 37 1-8 7/8 #6-32 36 1-12 59/64 #6-40 33 1 1/8-7 63/64 #8-32 29 1 1/8-12 1 3/64 #8-36 29 1 1/4-7 1 7/64 #10-24 24 1 1/4-12 1 11/64 #10-32 21 1 1/2-6 1 11/32 #12-24 17 1 1/2-12 1 27/64 #12-28 4.6mm 1 3/4-5 1 9/16 1/4-20 7 1 3/4-12 1 43/64 1/4-28 3 2-4 1/2 1 25/32 5/16-18 F 2-12 1 59/64 5/16-24 I 2 1/4-4 1/2 2 1/32 3/8-16 O 2 1/2-4 2 1/4 3/8-24 Q 2 3/4-4 2 1/2 7/16-14 U 3-4 2 3/4 7/16-20 25/64

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal

Equivalent

3x.50 #39 0.0995 3/32 3x.60 3/32 0.0937 3/32 4x.70 #30 0.1285 1/8 4x.75 1/8 0.125 1/8 5x.80 #19 0.166 11/64 5x.90 #20 0.161 5/32 6x1.00 #9 0.196 13/64 7x1.00 16/64 0.234 15/64 8x1.00 J 0.277 9/32 8x1.25 17/64 0.265 17/64 9x1.00 5/16 0.3125 5/16 9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 R 0.339 11/32 11x1.50 3/8 0.375 3/8 12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32

Nearest Fraction

DECIMAL EQUIVALENTS

1/64 . . . . . . . . . .. . . . . . . .0156

1/32. . . . . . .. . . . . . . .0312 . . .1 mm= .0394"

3/64 . . . . . . . . . .. . . . . . . .0469

1/16. . . . . . .. . . . . . . .0625

5/64 . . . . . . . . . .. . . . . . . .0781 . . .2 mm = .0787"

3/32. . . . . . .. . . . . . . .0938

7/64 . . . . . . . . . .. . . . . . . .1094 . . .3 mm =.1181"

1/8. . . . . . . . .1250

9/64 . . . . . . . . . .. . . . . . . .1406

5/32. . . . . . .. . . . . . . .1563 . . .4 mm = .1575"

11/64 . . . . . . . . . .. . . . . . . .1719

3/16. . . . . . .. . . . . . . .1875 . . .5mm= .1969"

13/64 . . . . . . . . . .. . . . . . . .2031

7/32. . . . . . .. . . . . . . .2188

15/64 . . . . . . . . . .. . . . . . . .2344 . . .6 mm = .2362"

1/4. . . . . . . . .25

17/64 . . . . . . . . . .. . . . . . . .2656 . . .7 mm = .2756"

9/32. . . . . . .. . . . . . . .2813

19/64 . . . . . . . . . .. . . . . . . .2969

5/16. . . . . . .. . . . . . . .3125 . . .8mm= .3150"

21/64 . . . . . . . . . .. . . . . . . .3281

11/32. . . . . .. . . . . . . .3438 . . .9 mm = .3543"

23/64 . . . . . . . . . .. . . . . . . .3594

3/8. . . . . . . . .375

25/64 . . . . . . . . . .. . . . . . . .3906 . . .10 mm = .3937"

13/32. . . . . .. . . . . . . .4063

27/64 . . . . . . . . . .. . . . . . . .4219 . . .11 mm =.4331"

7/16. . . . . . .. . . . . . . .4375

29/64 . . . . . . . . . .. . . . . . . .4531

15/32. . . . . .. . . . . . . .4688 . . .12 mm = .4724"

31/64 . . . . . . . . . .. . . . . . . .4844

1/2. . . . . . . . .5 . . . . . . . . . . . .13mm = .5118"

33/64 . . . . . . . . . .. . . . . . . .5156

17/32. . . . . .. . . . . . . .5313

35/64 . . . . . . . . . .. . . . . . . .5469 . . .14 mm = .5512"

9/16. . . . . . .. . . . . . . .5625

37/64 . . . . . . . . . .. . . . . . . .5781 . . .15 mm = .5906"

19/32. . . . . .. . . . . . . .5938

39/64 . . . . . . . . . .. . . . . . . .6094

5/8. . . . . . . . .625 . . . . . . . . . .16mm=. 6299"

41/64 . . . . . . . . . .. . . . . . . .6406

21/32. . . . . .. . . . . . . .6563 . . .17 mm =.6693"

43/64 . . . . . . . . . .. . . . . . . .6719

11/16. . . . . .. . . . . . . .6875

45/64 . . . . . . . . . .. . . . . . . .7031 . . .18 mm = .7087"

23/32. . . . . .. . . . . . . .7188

47/64 . . . . . . . . . .. . . . . . . .7344 . . .19 mm = .7480"

3/4. . . . . . . . .75

49/64 . . . . . . . . . .. . . . . . . .7656

25/32. . . . . .. . . . . . . .7813 . . .20 mm = .7874"

51/64 . . . . . . . . . .. . . . . . . .7969

13/16. . . . . .. . . . . . . .8125 . . .21 mm =.8268"

53/64 . . . . . . . . . .

27/32

55/64 . . . . . . . . . .. . . . . . . .8594 . . .22 mm = .8661"

7/8. . . . . . . . .875

57/64 . . . . . . . . . .. . . . . . . .8906 . . .23 mm = .9055"

29/32. . . . . .. . . . . . . .9063

59/64 . . . . . . . . . .. . . . . . . .9219

15/16. . . . . .. . . . . . . .9375 . . .24 mm = .9449"

61/64 . . . . . . . . . .. . . . . . . .9531

31/32. . . . . .. . . . . . . .9688 . . .25 mm = .9843"

63/64 . . . . . . . . . .. . . . . . . .9844

1 . . . . . . . . . 1.0

. . . . . . . .8281

. . . . . . . .8438

. . . . . .

1.10

GENERAL INFORMATION

CONVERSION TABLE

Unit of Measure Multiplied by Converts to

ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz.) x 28.3 5 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounc es (oz.) lb. x .454 = kg kg x 2.2046 = lb. Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in) Imperial pints (Imp pt.) x 0.568 = Liters (l) Liters (l) x 1.76 = Imperial pints (Imp pt.) Imperial quarts (Imp qt.) x 1.137 = Liters (l) Liters (l) x 0.88 = Imperial quarts (Imp qt.) Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.) US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.) US quarts (US qt.) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt.) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

π(3.14)xR

x H (height) = Cylinder Volume

°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: 5 (°F + 40)

÷ 9 - 40 = °C

1.11

GENERAL INFORMATION

GLOSSARY OF TERMS

ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center.

BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch . Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and

grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

CVT: Centrifugal Variable Transmission (Drive Clutch System)

DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder

bore.

Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire

touching the chassis).

End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt . ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

: Kilograms per square centimeter.

kg/cm kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter.

: Pounds per square inch.

lbs/in Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical

energy is converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts.

WOT: Wide open throttle.

1.12

CHAPTER 2

MAINTENANCE

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2

MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

LUBRICANTS / FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

POLARIS LUBES/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.7

POLARIS LUBRICANT SYMBOL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

VEHICLE INSPECTION / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

HAWKEYE HANDLEBAR COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . .2.9

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9

TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

FRONT GEARCASE LUBRICATION (4X4 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

LUBRICATION / GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

THROTTLE OPERATION - ALL MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

PILOT SCREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

ELECTRONIC THROTTLE CONTROL (ETC SWITCH)/THROTTLE CABLE ADJUSTMENT2.14

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

SPARK PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

MAIN AIR FILTER CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

AIR BOX SEDIMENT TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

CVT DRAIN PLUG & DRYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

TOE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

TOE ALIGNMENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

EXHAUST CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

BRAKE FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT. . . . . . . . . . . . . . 2.24

FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

REAR SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEEL, HUB, AND SPINDLE

TORQUE TABLE2.25

WHEEL REMOVAL/INSTALL- FRONT OR REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

2.1

MAINTENANCE

PERIODIC MAINTENANCE CHART

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, use genuine Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have

a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use 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, heavy load 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 or see your dealer.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an

authorized Polaris dealer.

= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50%

(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load o peration or exten ded idle . Mor e prev entat ive main tenanc e is required under these conditions. Fluid changes, cable, chain and chass is lubrication a re requ ired more f requent ly. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.)

E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

2.2

Improperly performing the procedures marked with

 could result in component failure and lead to

a serious injury or death. Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(KM)

Steering - Pre-Ride - Check for free operation. Front-suspension - Pre-Ride -



Rear-suspension - Pre-Ride -



Tires - Pre-Ride Engine Stop Switch - Check Operation

Brake fluid level - Pre-Ride -



Brake lever travel - Pre-Ride -



Brake systems - Pre-Ride Throttle - Pre-Ride - Check Operation Wheels /fasteners - Pre-Ride Frame Fasteners - Pre-Ride -



Engine oil level - Pre-Ride -



Air filter, pre-filter - Daily - Inspect;clean often



Air box sediment tube - Daily - Drain deposits when visible

Coolant (if applicable)

Headlamp/tail lamp - Daily Air filter,



main element

Recoil housing (if equipped)



Brake pad wear 10 H Monthly 100 (160) Inspect periodically



Battery 20 H Monthly 200 (320) Check terminals; clean; test Engine oil change



(break-in)

Front gearcase oil (if



equipped)



Middle gearcase oil (if equipped)

Rear gearcase oil



(if equipped) Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly



- Daily -

- Weekly - Inspect; replace as needed

-Weekly -

20 H 1M 10 0 (1 60 )

25 H Monthly 250 (400) Inspect level; change yearly

Make adjustments as needed. See PreRide Checklist on Page 2.8.

Make adjustments as needed. See PreRide Checklist on Page 2.8

Check level daily, change coolant every 2 years Check operation; apply dielectric grease if replacing

Drain water as needed, check often if operating in wet conditions

Perform a break-in oil change at one month

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

MAINTENANCE

Remarks

2.3

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(KM)

Engine breather



filter (if equipped)

Engine breather hose General



lubrication Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust



Steering 50 H 6 M 500 (800) Inspect daily, Lubricate



Front suspension 50 H 6 M 500 (800)



Rear suspension 50 H 6 M 500 (800)



Carburetor float bowl



Throttle Cable/

ETC Switch



Choke cable 50 H 6 M 500 (800)

Carburetor air

intake ducts/flange Drive belt 100 H 12 M 1000 (1600) Inspect; adjust; replace as needed Cooling system (if applicable) Engine oil change *Severe Duty



**Normal Duty Engine oil change

*Severe Duty

25 H Monthly 250 (400) Inspect; replace if necessary

100 H 6 M 1000 (1600) Inspect

50 H 3 M 500 (800)

50 H 6 M 500 (800) 50 H 6 M 500 (800)

50 H 6 M 500 (800)

500

25 H 50 H

25 H

6 M

12 M

6 M

(800) 1000

(1600)

500

(800)

Lubricate all grease fittings, pivots, cables, etc.

Inspect, Lubricate, Tighten Fasteners Inspect, Lubricate, Tighten

Fasteners Drain bowl periodically and prior to storage Inspect; adjust; lubricate; replace if necessary Inspect; adjust; lubricate; replace if necessary Inspect ducts for proper sealing/air leaks

Inspect coolant strength seasonally; pressure test system yearly

Perform a break-in oil change at 20

hours/one month, change more

frequently during cold weather

Replace at oil change

Remarks

**Normal Duty Oil filter change 100 H 6 M 1000 (1600) Replace with oil change



Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust



 Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services

50 H

12 M

1000

(1600)

2.4

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)



Fuel system 100 H 12M



Fuel Filter 100 H 12M

Radiator



(if applicable) Cooling hoses



(if applicable) Engine mounts 100 H 12M



Exhaust muffler / pipe



Spark plug 100 H 12M



Ignition Timing 100 H 12M

Wiring 100 H 12M



Clutches (drive



and driven) Front wheel



bearings

 Brake fluid 200 H 24M

Spark arrestor 300 H 36M

E Idle Speed - Adjust as needed

 Toe adjustment - Inspect periodica lly; adjust when part s are replaced



Auxiliary brake Pre- Ride Inspect daily; adjust as needed



Headlight aim - Adjust as needed

Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

100 H 12M

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

2000

(3200)

3000

(4800)

Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor, replace lines every two years

Replace yearly

Inspect; clean external surfaces

Inspect for leaks

Inspect

Inspect; replace as needed

Inspect Inspect for wear, routing, security; apply die lectric

grease to connectors subjected to water, mud, etc. Inspect;clean; replace worn parts

Inspect; replace as needed

Change every two years

Clean out

Remarks

2.5

MAINTENANCE

LUBRICANTS / FLUIDS

POLARIS LUBES/FLUIDS

ATV Angle Drive Fluid

0W/40

2874865 - Quarts 2874867 - 55 Gallon Drum

2.6

MAINTENANCE

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2874865 0W-50 Quarts 2874867 0W-50 55 Gallon Drum

Gearcase / Tra nsmission Lubricants

2873602

2873603

2871653

2872276

2870465 Oil Pump for 1 Gallon Jug

2871322

2871423

2871460 Starter Drive Grease (12 Count) 2871312 Grease Gun Kit 2871329 Dielectric Grease (Nyogel™)

Premium Synthetic AGL Gearcase Lube

(12 oz. bottle) (12 Count)

Premium Synthetic AGL Gearcase Lube

(1 Gal.) (4 Count)

Premium ATV Angle Drive Fluid

(8 oz.) (12 Count)

Premium ATV Angle Drive Fluid

(2.5 Gal) (2 Count)

Grease / Specialized Lubricants

Premium All Season Grease

(3 oz. cartridge) (24 Count)

Premium All Season Grease (14 oz. cartridge) (10 Count)

Part No. Description

Additives / Sealants / Thread Locking Agents /

Misc.

2870585 Loctite™ Primer N, Aerosol, 25 g

2871956

2871949

2871950

2871951

2871952

2871953

2871954

2870584

2870587

2871326

2870652 Fuel Stabilizer (16 oz.) (12 Count)

2871957

2871958

Loctite™ Thread Sealant 565

(50 ml.) (6 Count)

Loctite™ Threadlock 242

(50 ml.) (10 Count)

Loctite™ Threadlock 242

(6 ml.) (12 Count)

Loctite™ Threadlock 262

(50 ml.) (10 Count)

Loctite™ Threadlock 262

(6 ml.) (12 Count)

Loctite™ Threadlock 271

(6 ml.) (12 Count)

Loctite™ Threadlock 271

(36 ml.) (6 Count)

Loctite™ 680-Retaining Compound

(10 ml.)

Loctite™ 518 Gasket Eliminator / Flang e

Sealant (50 ml.) (10 Count)

Premium Carbon Clean

(12 oz.) (12 Count)

Black RTV Silicone Sealer

(3 oz. tube) (12 Count)

Black RTV Silicone Sealer

(11 oz. cartridge) (12 Count)

NOTE: Each item can be purchased separately at your local Polaris dealer.

2870990 DOT3 Brake Fluid (12 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.) 2872893 Engine Degreaser (12oz.) (12 Count)

NOTE: The number count indicated by each part number

in the table above indicates the number of units that are shipped with each order.

2.7

MAINTENANCE

POLARIS LUBRICANT SYMBOL IDENTIFICATION

NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenance section.

Polaris DOT 3 Brake Fluid

Polaris Synthetic Gearcase Lube

Polaris Synthetic OW-50 Oil

Polaris All Season Grease

Polaris ATV Angle Drive Fluid

VEHICLE INSPECTION / MAINTENANCE

PRE-RIDE / DAILY INSPECTION

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Tires - check condition and pressures

• Fuel and oil - fill both to their proper level; Do not overfill

• All brakes - check operation(includes auxiliary brake)

• Throttle - check for free operation

• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

• Engine stop switch - check for proper function

• Wheels - check for loose wheel nuts

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Engine coolant(if applicable) - check for proper level at the recovery bottle

2.8

HAWKEYE HANDLEBAR COMPONENT LOCATIONS

4x4 switch

Indicator Lights

Front Brake

Speedo

MAINTENANCE

(if applicable)

Light Control & Run Switch

Choke

Ignition/S tart Key

Reverse Override

MAINTENANCE QUICK REFERENCE

III. # Item Lube Rec. Method Frequency*

Change after 1st month (25 hours), 50 hours thereafter;

2 Transmission

Engine Oil Polaris 0W-50

Synthetic

Polaris AGL Lubricant

Add oil to proper level.

See procedure. Change annually2

Change more often (25 hours) in severe duty conditions, or short trip cold weather operation.

Throttle

3Brake Fluid

* More often under severe use, such as operated in water or under severe loads.

1 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) 2 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) 3 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special.

Rear Gearcase

A-Arm Bushings

Polaris DOT 3 Brake Fluid

Polaris A TV Angle Drive Fluid

Polaris All Season Grease 3

Fill master cylinder reservoir to indicated level inside reservoir.

Drain and refill with premeasured amount of lubricant.

Locate grease fitting on swing arm and grease with grease gun.

As required. Change fluid every 2 years.

As required*

Semi-annually 1

2.9

MAINTENANCE

NOTE: Refer to Page 2.6-2.8 for the Polaris Lubricant Identification table.

1. Engine Oil

Reservoir Level

3. Brake Fluid

5. Bottom Rear Lower Control Arm Lower Rear Bearing Carrier Pivot Prop Shaft

2. Transmission Oil

4. Rear Gearcase Oil

2.10

MAINTENANCE

TRANSMISSION LUBRICATION

The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding.

• Check vent hose to be sure it is routed properly and unobstructed.

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris AGSL Gearcase Lubricant:

(PN 2873603) (Gallon) (PN 2873602) (12 oz.)

Capacity:

Even with fill plug

Drain Plug and Fill Plug Torque:

15 ft. lbs. (20 Nm)

To change / check transmission fluid:

1. Place a drain pan beneath oil pan and remove drain plug from the crankcase. Allow oil to drain completely.

FRONT GEARCASE LUBRICATION (4X4 ONLY)

The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding.

• Check vent hose to be sure it is routed properly and unobstructed.

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:

Polaris Premium Demand Drive Hub Fluid: (PN 2872277) (2.5 gallon) (PN 2871654) (8 oz.)

Capacity:

Even with fill plug

Drain Plug Torque:

8-10 ft. lbs. (11-13 Nm)

Fill / Check Plug Torque:

8-10 ft. lbs. (11-13 Nm)

2. Reinstall the drain pl ug . Tighten to specification.

3. Add the proper amount of lubricant to bring level into operating range as shown. Do not over fill.

Drain Plug

Gearcase oil flush with the bottom of thread area.

4. Verify fluid level is correct and no leaks are present.

Oil Level Check

1. Position the vehicle on a level surface.

2. Remove the check/fill plug (A) and view the oil level. The oil level should be at the bottom of the check plug (B) threads.

3. Reinstall the check/fill plug (A). Torque to specification.

4. Reinstall the check plug (A) and a new sealing washer. Torque to specification.

2.11

MAINTENANCE

5. Check for leaks.

Oil Change

1. Remove the drain plug (C). Drain the oil into an appropriate container. Discard used oil properly

2. Clean and reinstall the drain plug with a new sealing washer. Torque to specification.

3. Remove the check plug (A).

4. Remove the fill plug (B) and add a pre-measured amount of Polaris Angle Drive Fluid. The fluid should not be above the bottom of the check plug (A) threads.

5. Reinstall the fill plug (B) and check plug (A). Torque to specification.

6. Check for leaks.

LUBRICATION / GREASE POINTS

There are grease zerks rear lower control arm inner pivots, lower rear bearing carrier pivots, and the prop shaft. Apply grease until it is visible on the ends of the pivot points.

THROTTLE OPERATION - ALL MODELS

Check for smooth throttle opening and closing in all han dlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.

1. Place the gear selector in neutral.

2. Set parking brake.

Verify free play of 1/16-3/16” (1.6-4.76 mm) and smooth operation of choke cable.Adjustments to the freeplay can be made by loosening the choke cable adjustment in or out to gain the desired freeplay.

If smooth choke operation is not obtainable, inspect choke cable for kinks or sharp bends in routing.

CARBURETOR DRAINING

The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage.

NOTE: The bowl drain screw is located on the bottom left side of the float bowl.

1. Turn fuel valve to the OFF position.

2. Place a clean container beneath the bowl drain spigot or bowl drain hose.

3. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely.

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turn fuel valve to “ON”.

7. Start machine and check for leaks.

NOTE: All tubes attached to the carburetor must be check for pinching or blockage, as this will effect engine performance

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition. If cable is routed properly and in good condition, repeat adjustment procedure.

5. Replace the throttle cable if worn, kinked, or damaged.

CHOKE (ENRICHER) ADJUSTMENT

CHOKE

2.12

Drain tube attached here

III. 1

Drain Screw

MAINTENANCE

PILOT SCREW

The pilot system supplies fuel during en gine operatio n wi th the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet.

CAUTION

The pilot screw is calibrated at the factory to m eet EPA / CARB regulations for air quality standards and is sealed with a brass plug to prevent tampering. Removal of the tamper proof plug is not permitted. For service purposes, cleaning of the pilot circuit can be done only by a certified repair shop to ensure air quality standards are not exceeded.

PILOT SCREW ADJUSTMENT

FRONT

(Engine)

Pilot Screw

Pilot Screw Location

Brass Plug Installed

Brass Plug Removed

1. Start engine and warm it up to operating temperature (about 10 minutes).

2. Turn pilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns. NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged.

Pilot screws are calibrated at the factory. Each carburetor has a slightly different pilot screw setting. The specifications may require additional tuning to achieve the desired results.

3. Connect an accurate tachometer that will read in increments of + or - 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN 8712500).

4. Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

5. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss.

2.13

MAINTENANCE

6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop.

7. Center the pilot screw between the points in Step 5 and 6.

8. Re adjust idle speed if not within specification.

ELECTRONIC THROTTLE CONTROL (ETC SWITCH)/THROTTLE CABLE ADJUSTMENT

1. Slide the boots off inline cable adjuster sleeve. Loosen adjuster locknut.

2. With handlebars centered and wheels pointing forward, turn adjuster sleeve until 1/16” - 1/8” freeplay is achieved at the thumb lever. After making any adjustment, “flip” the lever slightly to confirm adjustment.

Boot

Adjuster Sleeve

Locknut

Boot

• Do not overfill the tank. Do not fill the tank neck.

• If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately.

• If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time.

• Never drain the float bowl when the engine is hot. Severe burns may result.

FUEL LINES

1. Check fuel lines for signs of wear, deterioration, damage, or leakage. Replace if necessary.

2. Be sure fuel lines are routed properly and secured with cable ties.

CAUTION

Make sure lines are not kinked or pinched

Direction of travel

3. Tighten locknut and slide boots over cable adjuster until they touch at the middle point of the adjuster.

4. With engine running, turn the handlebars from full left to full right with transmission in neutral. Engine RPM should not change and the engine should not die. If either of these occur, return to the first step.

NOTE: If the throttle cable is adjusted too tight, the ETC will limit operation at low throttle positions.

1/16” to 1/8” Freeplay

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

• Always stop the engine and refuel outdoors or in a

well ventilated area.

• Do not smoke or allow open flames or sparks in or

near the area where refueling is performed or where gasoline is stored.

3. Replace all fuel lines every two years.

VENT LINES

1. Check fuel tank, crankcase, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

2. Verify vent lines are routed properly and secured with cable ties.

CAUTION

Make sure lines are not kinked or pinched

FUEL FILTER

The fuel filter should be replaced in accordance with the Periodic Maintenance Chart. The fuel filter is located between the fuel tank and carburetor.

1. Clamp fuel lines

2. Remove line clamps at both ends of the filter.

3. Remove fuel lines from filter.

4. Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow.

2.14

MAINTENANCE

BATTERY MAINTENANCE

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:

Fuel Filter

To Carburetor

5. Install clamps on fuel line.

6. Start engine and inspect for leaks.

7. Remove clamps

COMPRESSION TEST

NOTE: This 4-Stroke engine is equipped with an

automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 90 psi compression test.

Smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by a decompressor malfunction, or worn or damaged exhaust cam lobes. Inspect camshaft and automatic decompression mechanism if compression is abnormally high.

A cylinder leakage test is the best indication of engine condition on models with automatic decompression. Follow tester manufacturer’s instructions to perform a cylinder leakage test. (Never use high pressure leakage testers as crankshaft seals may dislodge and leak).

Cylinder Compression

Standard: 90PSI

Cylinder Leakage

Service Limit: 10%

(Inspect for cause if leakage exceeds 10%)

during a

External: Flush with water. Internal: Drink large quantities of water or milk. Fol-

low 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.

NOTE: All Hawkeye batteries are Low Maintenance design and construction. All Low Maintenance batteries are fully charged and tested at the factory before installation. Expected shelf life is 6-8 months depending on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly.

Low Maintenance batteries are permanently sealed at the time of manufacture. The use of lead-calcium and AGM technology instead of lead-antimony allows the battery acid to be fully absorbed. For this reason, a Low Maintenance battery case is dark and the cell caps are not removable, since there is no need to check electrolyte level.

NEVER attempt to add electrolyte or water to a Low Maintenance battery. Doing so will damage the case and shorten the life of the battery. Refer to the Battery Maintenance Video (PN 9917987) for proper instruction on servicing Low Maintenance batteries.

ENGINE MOUNTS

Inspect rubber engine mounts for cracks or damage.

ENGINE FASTENER TORQUE

Check engine fasteners and ensure they are tight

2.15

MAINTENANCE

The battery is located under front rack.

To remove the battery:

1. Disconnect holder strap.

2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable.

CAUTION

To reduce the chance of sparks: Whenever removing the battery, disconnect the negative (black) cable first. When reinst alling the battery, install the negative cable last.

SPARK PLUG

1. Remove the seat and left hand side panel.

2. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is removed.

3. Remove spark plug.

4. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.

Inspect electrode for wear and buildup

Spark Plug Gap

3. Remove the battery.

4. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Rinse well with clean water and dry thoroughly.

5. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable.

6. Coat terminals and bolt threads with Dielectric Grease (PN

2871329).

7. Reinstall battery cover and holder strap.

5. Clean with electrical contact cleaner or a glass bead spark

plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.

6. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side electrode carefully.

7. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

8. Apply a small amount of anti-seize compound to the spark plug threads.

9. Install spark plug and torque to 9-11 ft. lbs (12-14 Nm).

2.16

MAINTENANCE

10. Replace side panel and seat.

Recommended Spark Plug:

NGK R7HSA

Spark Plug Torque: 9-11 Ft. Lbs.

(12 - 14 Nm)

IGNITION TIMING

Timing is CDI controlled and has no adjustment procedure.

Ignition Timing:

+ 2o BTDC@3000RPM

MAIN AIR FILTER CLEANING

It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observe the following practices.

• Never immerse the filter in water since dirt can be transferred to the clean air side of the filter.

• If compressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside.

• Replace the air filter every 50 hours, and possibly more often in very dirty conditions.

AIR FILTER/PRE-FILTER SERVICE

It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often.

The pre filter should be cleaned before each ride using the following procedure:

2. Remove clips from air box cover (A) and remove cover.

3. Inspect the gasket. It should adhere tightly to the cover and seal all the way around.

4. Remove air filter assembly.

Cleaning:

5. Slip the pre-filter element off of main element. Clean the pre filter with hot soapy water.

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

8. Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.

Installation:

9. Reinstall pre-filter element over main filter. Be sure the element covers entire surface of main filter without folds, creases, or gaps.

10. Reinstall filter on main filter mount. Place filter clamp over the assembly and tighten.

NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling.

1. Remove the seat.

2.17

MAINTENANCE

Proper Filter Placement

Filter Support

Air Box

Main Filter

CVT DRAIN PLUG & DRYING

NOTE: If operating the ATV through water, be sure to

check the CVT and other components for water ingestion. The ATV should be checked immediately.

1. To release any water that maybe trapped in the CVT cover, simply remove the CVT drain plug and O-ring located on the bottom of the CVT cover and let the water drain out.

III. 3

NOTE: The air filter should rest on the filter support. Proper placement of the air filter is important to prevent rattles and air leaks. See Illustration above.

11. Install air box cover and secure with clips.

Rear

AIR BOX SEDIMENT TUBE

Periodically check the air box drain tube located toward the rear of the machine. Drain whenever deposits are visible in the clear tube.

Sediment Tube

2. To further expel water from the cover and to dry out the CVT system, shift the transmission to neutral and rev engine slightly to expel the moisture and air-dry the belt and clutches. Allow engine RPM to settle to idle speed, shift transmission to lowest available range and test for belt slippage. Operate ATV in lowest available range for a short period of time until CVT system is dry.

ENGINE OIL LEVEL

To check the oil level:

1. Set machine on a level surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

NOTE: The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

1. Remove drain plug from end of sediment tube.

2. Drain Tube.

3. Reinstall drain plug.

2.18

4. Start the engine. Allow it to idle for 30 seconds.

5. Turn the engine off.

6. The oil dipstick and fill hole are located behind the recoil on

+ 187 hidden pages

Polaris Hawkeye, 2006 HAWKEYE 2x4, 2006 Hawkeye 4x4 Repair Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL INFORMATION

VEHICLE IDENTIFICATION

Model Identification

Engine Designation Number

Vehicle Identification Number (VIN)

Vehicle and Engine Serial Number Locations

SPECIFICATIONS

MODEL: 2006 HAWKEYE 2x4

MODEL: 2006 HAWKEYE 2x4

MODEL: 2006 HAWKEYE 4x4

GENERAL INFORMATION

PUBLICATION NUMBERS

REPLACEMENT KEYS

SPECIAL TOOLS

STANDARD TORQUE SPECIFICATIONS

SAE TAP DRILL SIZES

METRIC TAP DRILL SIZES

DECIMAL EQUIVALENTS

CONVERSION TABLE

GLOSSARY OF TERMS

MAINTENANCE

MAINTENANCE

PERIODIC MAINTENANCE CHART

Maintenance Chart Key

MAINTENANCE AND LUBRICATION

LUBRICANTS / FLUIDS

POLARIS LUBES/FLUIDS

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

POLARIS LUBRICANT SYMBOL IDENTIFICATION

VEHICLE INSPECTION / MAINTENANCE

PRE-RIDE / DAILY INSPECTION

HAWKEYE HANDLEBAR COMPONENT LOCATIONS

MAINTENANCE QUICK REFERENCE

TRANSMISSION LUBRICATION

FRONT GEARCASE LUBRICATION (4X4 ONLY)

LUBRICATION / GREASE POINTS

THROTTLE OPERATION - ALL MODELS

CARBURETOR DRAINING

CHOKE (ENRICHER) ADJUSTMENT

PILOT SCREW

PILOT SCREW ADJUSTMENT

ELECTRONIC THROTTLE CONTROL (ETC SWITCH)/THROTTLE CABLE ADJUSTMENT

FUEL LINES

FUEL SYSTEM

VENT LINES

FUEL FILTER

BATTERY MAINTENANCE

COMPRESSION TEST

ENGINE MOUNTS

ENGINE FASTENER TORQUE

SPARK PLUG

IGNITION TIMING

MAIN AIR FILTER CLEANING

AIR FILTER/PRE-FILTER SERVICE

CVT DRAIN PLUG & DRYING

AIR BOX SEDIMENT TUBE

ENGINE OIL LEVEL