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Polaris Hawkeye General Information Manual

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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
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   Summary of Contents for Polaris Hawkeye

  • Page 1: General Information


  • Page 2: Model Identification, Engine Designation Number, Vehicle Identification Number (vin), 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 number is stamped on the center top of crankcase beneath the cylinder coolant elbow.

  • Page 3: Specifications

    75 lbs./34 kg Body Style Recreational/Utility ... . 2006 HAWKEYE 4x4 MODEL: MODEL NUMBER: ..A06LD27AA ENGINE MODEL: ..ES30PFE...

  • Page 4

    Spark plug / Gap NGK CR8E .031 in. / .8 mm 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...

  • Page 5

    Spark plug / Gap NGK CR8E .031 in. / .8 mm 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...

  • Page 6: Publication Numbers, Replacement Keys, General Information

    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.

  • Page 7: Special Tools

    Standard Tools and Engine 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.

  • Page 8

    PV-43568 - Fluke 77 Multimeter 2870303- Hone Kit PV-39617 - Current Clamp 2870305 - Stone Replacement Kit 2870836 - Battery Hydrometer 8712500 - PV-39951-A 2870588 - Hone Oil (12 OZ.) Tachometer Tachometer 2200634 - Valve Seat Reconditioning Kit 2870459 - Dial Indicator...

  • Page 9: Standard Torque Specifications

    13 ....50(69) ..75 (104) ..

  • Page 10: Sae Tap Drill Sizes, Metric Tap Drill Sizes, Decimal Equivalents

    5/32 ....1563 . . .4 mm = .1575" #3-56 3/4-10 21/32 11/64 ....1719 #4-40 3/4-16 11/16 3/16 .

  • Page 11: Conversion Table

    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...

  • Page 12: Glossary Of Terms

    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.

  • Page 13: Table Of Contents


  • Page 14: Periodic Maintenance Chart, Maintenance Chart Key

    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.

  • Page 15: Maintenance And Lubrication

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

  • Page 16

    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...

  • Page 17

    Inspect periodically; adjust when parts 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.

  • Page 18: Lubricants / Fluids

    - - MAINTENANCE LUBRICANTS / FLUIDS POLARIS LUBES/FLUIDS 0W/40 2874865 - Quarts 2874867 - 55 Gallon Drum ATV Angle Drive Fluid...

  • Page 19: Polaris Lubricants,maintenance And Service Products

    DOT3 Brake Fluid (12 Count) local Polaris dealer. 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.

  • Page 20: Polaris Lubricant Symbol Identification, Vehicle Inspection / Maintenance, Pre-ride / Daily Inspection

    - - 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 ATV Polaris Synthetic Polaris All Season Grease Polaris DOT 3 Polaris Synthetic...

  • Page 21: Hawkeye Handlebar Component Locations, Maintenance Quick Reference

    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.

  • Page 22

    - - MAINTENANCE NOTE: Refer to Page 2.6-2.8 for the Polaris Lubricant Identification table. 1. Engine Oil 2. Transmission Oil Reservoir Level 3. Brake Fluid 4. Rear Gearcase Oil 5. Bottom Rear Lower Control Arm Lower Rear Bearing Carrier Pivot Prop Shaft 2.10...

  • Page 23

    • Be sure vehicle is level before proceeding. • Be sure vehicle is level before proceeding. • Check vent hose to be sure it is routed properly and unobstructed. • Check vent hose to be sure it is routed properly and unobstructed.

  • Page 24: Carburetor Draining, Lubrication / Grease Points, Throttle Operation - All Models, Choke (enricher) Adjustment

    Remove the drain plug (C). Drain the oil into an appropriate made by loosening the choke cable adjustment in or out to gain container. Discard used oil properly the desired freeplay.

  • Page 25

    Brass Plug Removed 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). Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

  • Page 26: Fuel Filter, Electronic Throttle Control (etc Switch)/throttle Cable Adjustment, Fuel Lines, Vent Lines, Fuel System

    - - MAINTENANCE Slowly turn mixture screw counterclockwise until idle • Do not overfill the tank. Do not fill the tank neck. speed increases to maximum RPM. Continue turning • If you get gasoline in your eyes or if you swallow counterclockwise until idle RPM begins to drop.

  • Page 27: Battery Maintenance, Engine Mounts, Engine Fastener Torque

    For this reason, a Low Maintenance battery case is condition on models with automatic decompression. Follow dark and the cell caps are not removable, since there is no need tester manufacturer’s instructions to perform a cylinder leakage to check electrolyte level.

  • Page 28: Spark Plug

    Remove the seat and left hand side panel. Disconnect holder strap. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is removed. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable.

  • Page 29: Ignition Timing

    MAIN AIR FILTER CLEANING Remove air filter assembly. It is advisable to replace the filter when it is dirty. However, in Cleaning: an emergency it is permissible to clean the main filter if you observe the following practices.

  • Page 30: Cvt Drain Plug & Drying, Air Box Sediment Tube, Engine Oil Level

    The ATV should be checked immediately. Support 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. Air Box Rear III. 3 NOTE: The air filter should rest on the filter support.

  • Page 31: Oil And Filter Change

    CAUTION Remove the dipstick and wipe it clean. Reinstall the dipstick completely Hot oil may result in serious burns. Do not allow hot oil to contact skin. Remove the dipstick an check the oil level. 10. Add oil as needed to bring the level between the minimum Place a drain pan under the vehicle.

  • Page 32: Valve Clearance Adjustment

    21. Turn off the engine. Check for oil leaks. Re-check the valve clearance. 22. Check the oil level. Add oil as needed to bring the level Repeat adjustment procedure if necessary until clearance is between the min. and max marks. Do not overfill.

  • Page 33: Camber And Caster, Tie Rod End/steering Inspection, Toe Alignment

    CAMBER AND CASTER TIE ROD END/STEERING INSPECTION The camber and caster are non-adjustable. To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement. TOE ALIGNMENT • Repeat inspection for inner tie rod end (on steering Place machine on a smooth level surface.

  • Page 34: Toe Alignment Adjustment, Exhaust Cleaning

    EXHAUST CLEANING If toe alignment is incorrect, measure the distance between WARNING vehicle center and each wheel. This will tell you which tie rod needs adjusting. NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment.

  • Page 35: Brake Pad Inspection, Brake System Inspection, Hose/fitting Inspection, Brake Freeplay

    Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks.Tighten any loose fittings and replace any • Check the fluid level “eye”. If it is clear, it is an worn or damaged parts. indication that fluid is needed or the brake pads may be worn, which can reduce the fluid level.

  • Page 36: Suspension Spring Front / Rear Preload Adjustment

    Hand Brake Lever Free Play Rear Foot Brake Rear Brake Check foot brake effectiveness by applying approximately 50 lb. (23 kg) downward force on the pedal. The top of the pedal should travel not more than 1 inch (25.4mm). 1” or greater 50 lbs...

  • Page 37: Wheel Removal/install- Front Or Rear, Front Suspension Inspection, Rear Suspension Inspection

    • Check all rear suspension components for wear or With the transmission in gear and the parking brake locked, damage. place the wheel in the correct position on the wheel hub. Be • Inspect shock for leakage. sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

  • Page 38: Tire Inspection

    MAINTENANCE WHEEL INSTALLATION Tire Tread Depth Always replace tires when tread depth is worn to 1/8” (3 mm) With the transmission in gear and the parking brake locked, or less. place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

  • Page 39: Table Of Contents


  • Page 40: Table Of Contents


  • Page 41

    - - ENGINE TOOLS Oil Pressure Blind Plug 1/4 NPT 20-24 (27-33 Nm) SPECIAL TOOLS Oil Pressure Relief 14 mm 15-17 (20-23 Nm) Valve Plug PART NUMBER TOOL DESCRIPTION Recoil Housing 7-8 (9-11 Nm) Valve Seat 2200634 Rocker Adjuster Screw 3.5-5 (5-7 Nm)

  • Page 42: Torque Patterns

    3) Loosen 180 degrees 4) Tighten to 11 ft. lbs. (15 Nm) 5) Tighten 90 degrees 6) Tighten 60 degrees 7) Tighten 6mm head and base bolts to 8 ft. lbs. (11 Nm) Cylinder Head / Cylinder Base 6 mm...

  • Page 43: General Engine Service, Engine Exploded View

    - - ENGINE GENERAL ENGINE SERVICE ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head 6 ft. lbs. 8 ft. lbs. 15 ft. lbs. 15 ft. lbs. PROCEDURE 12-14 ft. lbs. 5.5 ft. lbs. 16 ft. lbs. 5.5 ft. lbs. Crankshaft...

  • Page 44: Engine Service Data

    Stem to Guide Oil Clearance Limit .006" (.15 mm) Valve Spring Free Length 1.640" (41.66 mm) 1.377" (35.0 mm) Squareness 0.075” (1.9 mm) KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off...

  • Page 45

    Degree of fit Push (by hand) fit @ 68 F (20 C) (Standard clearance 0-.0005" (0-.012mm) Piston Ring Piston Ring Installed Gap Top ring Std .008-.0012" (.2-.3 mm) Limit .032" (.8 mm) Second .018-.019" (.35-.50 mm) ring Limit .039" (1.0mm) Oil ring .0079-.0275"...

  • Page 46

    Pump Feed Rotor to Pump Body Clearance Limit Above 9 PSI Oil Pressure (Polaris 0W-50 @ Normal Operating Temperature @ Idle Speed) Limit Below 9 PSI KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off.

  • Page 47: Oil Flow Diagram

    Rocker Arm Rocker Shaft Valve Springs ES300PFE010 Chain Room Camshaft Cylinder Head Sprocket & Chain (RH Cam Journal) Connecting Rod Small End Piston Skirt / Rings Right Rear Nozzle Cylinder Bolt Counter Balance Gear Crankshaft Main Bearing Connecting Rod Big End...

  • Page 48: Piston Identification, Piston Ring Identification, Engine Service, Engine Removal, Accessible Components

    Replace crankshaft as an assembly. PISTON RING IDENTIFICATION ENGINE SERVICE The piston ring profile is shown below. Install top and second ring with marking UP. Refer to text for oil control ENGINE REMOVAL ring installation. NOTE: The engine removal procedure described...

  • Page 49

    13. CVT air intake and exhaust ducts 14. Remove carburetor. Insert a clean shop towel into the 8. Front prop shaft (4x4 models) (Drive pin out at front carburetor flange to prevent dirt from entering the gearcase, pull shaft back, then forward. Refer to Drive intake port.

  • Page 50

    - - ENGINE 17. Recoil housing, flywheel and stator (or if front cab is 23. Top rear shock bolts. removed, remove front cab and disconnect wires.) 24. Top bolts from sway bar bracket. See “Flywheel Removal / Inspection” on page 3.28. for 25.

  • Page 51: Engine Installation Notes

    26. Support engine and remove (9) transmission-to- Engine Break In Period engine bolts. 4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel. • Use only Polaris Premium 4 All Season Synthetic Oil, or API certified “SH”...

  • Page 52: Transmission Removal

    11. Rear fuel tank bracket. 12. CVT air inlet duct. 7. Front prop shaft (4x4 models) (Drive pin out at front gearcase, pull shaft back, then forward. Refer to Drive Chapter) 13. Support frame under engine with a stable platform jack.

  • Page 53: Transmission Installation Notes

    - - ENGINE 15. Remove rear plate (lower control arm bolts) and upper 22. Loosen, but do not remove the 4 bolts from the rear control arm bolts. transmission hanger bracket. 16. Remove rear shocks. 23. Remove (9) transmission-to-engine bolts.

  • Page 54: Engine Lubrication, Cam Chain Tensioner Removal, Oil Flow / Pressure Test

    - - ENGINE ENGINE LUBRICATION CAM CHAIN TENSIONER REMOVAL Oil Type: ..Polaris Premium 0W-50 Synthetic To position crankshaft at Top Dead Center (TDC) on compression stroke: Capacity (DRY): 1.64-1.95 U.S. Quarts (1.55-1.85 l) 4.

  • Page 55: Rocker Arm/shaft Disassembly And Inspection, Cam Chain Tensioner Inspection

    TDC on the compression stroke (there should be clearance on both rocker arm adjusters). CAM CHAIN TENSIONER INSPECTION 1. Pull cam chain tensioner plunger (A) out to the end of its travel and inspect ratchet teeth on plunger and pawl. Inspect spring (B) for wear or damage.

  • Page 56: Camshaft Removal And Inspection

    - - ENGINE 5. Inspect the rocker arm shaft and the shaft bore in the 4. If not removing the cylinder for other service, secure cylinder head for wear or signs of scoring. the cam chain with a wire to prevent it from falling into the crankcase.

  • Page 57: Cylinder Head Removal

    Replace cam if worn below minimum height (service limit). 3. Remove bolts (A) and tap the cam support tower with a plastic hammer until loose. Remove. 4. After removing the camshaft and securing the cam chain, tap cylinder head lightly with a plastic hammer until loose.

  • Page 58: Cylinder Head Warp Inspection, Combustion Chamber Inspection, Cylinder Head Disassembly

    3. Push valve out, keeping it in order for reassembly in the same guide. 1. Lay a straight edge across the surface of the head at 4. Measure free length of the inner and outer springs several different points and measure warpage by with a Vernier caliper, Ill.1.

  • Page 59: Valve Seat Reconditioning

    6. Measure valve guide inside diameter at the top middle VALVE INSPECTION and end of the guide using a small hole gauge and a 1. Remove all carbon from valve with a soft wire wheel. micrometer. Measure in two directions, front to back and side to side.

  • Page 60

    If the pilot is bent it must be replaced. NOTE: Valve seat width and point of contact on the valve • If the contact area of the cutter is in the same place, face is very important for proper sealing. The valve must...

  • Page 61

    8. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air. • If the indicated seat contact is at the top edge of the 9. Lubricate the valve guides with clean engine oil, and...

  • Page 62: Valve Sealing Test

    7. Repeat procedure for remaining valve. NOTE: Assemble the valves one at a time to maintain 8. When all valves are installed, tap lightly with soft faced proper order. hammer on the end of the valves to seat the Split keepers.

  • Page 63: Engine Bottom End Disassembly, Piston Removal, Cam Chain Guide And Tesioner Blade

    If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply 1. Lift to remove cam chain guide at front of cylinder. heat to the piston rings. The ring may lose radial 2. Remove the two 6 mm cylinder base bolts.

  • Page 64

    1. Remove all gasket material from the cylinder sealing surfaces. CAUTION 2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. A hone which will straighten as well as remove ma- terial from the cylinder is very important. Using a common spring loaded glaze breaker for honing is not advised.

  • Page 65: Piston Inspection

    EXAMPLE OF CROSS HATCH PATTERN PISTON INSPECTION 1. Measure piston outside diameter at a point 7 mm up from the bottom of the piston at a right angle to the direction of the piston pin. Piston Pin Measurement Locations 5. Measure connecting rod small end ID. Replace crankshaft if out-of-round.

  • Page 66: Flywheel Removal / Inspection

    Oil Ring Std: .008- .028” (0.2- 0.7 mm) Limit: .059” (1.5 mm) 2. Measure the gap with a feeler gauge at both the top and bottom of the cylinder. NOTE: Measure at two points in the cylinder A difference in end gap indicates cylinder taper. The...

  • Page 67

    2. Remove the starter drive clutch and washer by pulling stator. the shaft and tilting the gear slightly. 3. Measure the OD of the starter drive shaft on both ends Using the Slotted Nut Socket, remove the crankshaft for out-of-round.

  • Page 68: Oil Pump Inspection / Removal

    2. Use a feeler gauge to check oil pump rotor tip Inspect the starting clutch drum bearing in the clearance at “A”, and pump body clearance at “B”.

  • Page 69: Starting Clutch Assembly

    - - ENGINE 5. Open the staked portion of the nut (A) with a center 8. Inspect the shoes and springs of the starting clutch. punch. Inspect the one-way clutch hub surface on the Measure the thickness of the friction material on the starting clutch (B).

  • Page 70: Crankcase Separation

    14-15.5 ft. lbs. (19-21 Nm) crankcase evenly. 3. Lift the right case half off of the left, leaving the 12. CHECK the clutch shaft to be sure it rotates smoothly crankshaft and balance shaft in the left case. in the clockwise direction and will not rotate in the counterclockwise direction.

  • Page 71: Crankshaft Removal, Crankshaft / Cam Chain / Sprocket Inspection

    The inner race of PTO bearing each bearing should fit tightly on the crankshaft. The outer race should be firm with minimal side to side movement and no detectable up and down movement. The MAG end bearing usually stays in the case. Check the inner race of the MAG bearing in the same manner.

  • Page 72: Crankcase Oil Pickup Strainer Inspection, Camshaft Chain, Bearing /seal Installation, Balance Shaft Bearing Inspection

    2. The cam chain can be removed by removing the engine top end, the recoil assembly, flywheel and 1. Pull the strainer screen (A) from the case carefully and flywheel key, stator plate, and slotted nut. clean or replace it if heavily clogged, or if damaged.

  • Page 73: End Play Inspection/adjustment, Crankshaft End Play Adjustment

    2. Lay a straightedge on the left (PTO) crankcase and measure the distance from the straightedge to the bottom of the main bearing bore (if bearing is still on the crankshaft) or to the bearing race (if the bearing is installed in the case) using a dial caliper.

  • Page 74: Counter Balancer Shaft End Play Adjust

    - - ENGINE 6. Add the readings recorded in Step 3 and Step 5 and COUNTER BALANCER SHAFT END PLAY record below. ADJUST. NOTE: The counterbalance shaft end play measurement procedure is the same as that outlined Total Case Width_________________ for the crankshaft.

  • Page 75: Crankcase Reassembly

    PN 2871557 5. Install the mag side case and tap with a soft faced hammer to seat. Install case screws and torque in a cross pattern to specification.

  • Page 76: Cam Chain, Oil Pump, & Tensioner Blade Installation

    6. IMPORTANT! Be sure the sealed screw is placed in the hole that aligns with the cam chain cavity or an oil leak may result. If you are installing the old screw seal...

  • Page 77: Piston Ring Installation, Piston Installation

    The ends should butt squarely together and must not overlap. 2. Install the oil ring top rail with the end gap at least 30 from the end of the expander. 3. Install the bottom rail with the gap at least 30...

  • Page 78: Cylinder Installation, Cylinder Head And Camshaft Installation

    4. Apply clean engine oil liberally to the bore and tapered area of the cylinder. Place the cylinder on to the studs. 4. Install the two 6 mm bolts on cylinder base and on the head, but do not tighten.

  • Page 79: Camshaft Installation & Timing

    • Tighten to 11 ft. lbs. (15 Nm) • Tighten 90 degrees • Tighten 60 degrees • Tighten 6mm head & base bolts to 8 ft.lbs.(11 Nm) 4. Disconnect the wire or tie strap securing the cam chain (if used).

  • Page 80: Rocker Arm Installation, Cam Chain Tensioner Installation

    - - ENGINE 6. Loop the cam chain over the sprocket and shift the assembly with a new gasket and tighten the bolts to chain on the sprocket until it can be installed onto the specification. camshaft. Tensioner Bolt Torque: 7.

  • Page 81: Starter Drive Assembly, Spark Plug Fouling Troubleshooting

    2. Slide the shaft through the tower just enough to install STARTER DRIVE ASSEMBLY the wave washer (A). 1. Be sure the washer is positioned on the back of the NOTE: The flats of the wave washer are positioned drive gear.

  • Page 82: Engine Troubleshooting

    • Starter motor does not turn • Lack of lubrication • Engine seized, rusted, or mechanical failure • Dirt entering engine through cracks in air filter or ducts Engine Runs But Will Not Idle • Engine oil dirty or contaminated •...

  • Page 83

    • Rocker arm sticking Backfiring • ETC or speed limiter system malfunction • Fouled spark plug or incorrect plug or plug gap • Carburetion faulty - lean condition • Intake / Exhaust system air leaks • Ignition system faulty: •Spark plug cap cracked/broken...

  • Page 84

    - - ENGINE NOTES 3.46...

  • Page 85: Table Of Contents


  • Page 86

    Always stop the engine and refuel outdoors or in a well ventilated area. Do not overfill the tank. The tank is at full ca- pacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel.

  • Page 87: Bst 34 Carburetor Exploded View 1 Of

    - - FUEL SYSTEM / CARBURETION CARBURETITION BST 34 Carburetor Exploded View 1 of 2 Table 4-1: Carburetor Components Reference Description Reference Description Jet Needle Throttle Control Cover Plate Diaphragm Assembly Carburetor Body Needle Jet Enrichment Plunger Jet Block Assembly...

  • Page 88: Bst 34 Carburetor Exploded View 2 Of

    - - FUEL SYSTEM / CARBURETION BST 34 Carburetor Exploded View 2 of 2 Table 4-2: Carburetor Components Reference Description Reference Description Throttle Plate Shaft Retaining Components Float Bowl O Ring Pilot Jet Float Bowl Needle Valve Assembly Float Bowl Drain Screw...

  • Page 89: Carburetor Venting System

    - - FUEL SYSTEM / CARBURETION Carburetor Venting System Table 4-3: Carburetor Venting System Reference Description Check Valve Hose (Float Bowl Drain) Hose (Vents) Tee Fitting Filter...

  • Page 90: Carburetor Specifications, Cv Carburetor System Function, Carburetor Jetting, Mikuni Jet Part Numbers

    Starter Bleed settings and CAUTION Pipe) idle A main jet that is too small will cause a lean operat- Pilot (Idle Pilot Jet/ Primarily Mainly idle ing condition resulting in serious engine damage. System) Passage-ways,...

  • Page 91: Carburetor Venting, Mikuni Cv Carb Operation

    (and The carburetor float bowl vent lines supply atmospheric therefore in the chamber above the diaphragm) becomes pressure to the float bowl. The lines must be free of kinks, significantly lower than atmospheric.

  • Page 92: Starter System (choke Or Enrichment), Pilot (idle And Slow) System

    (1) or slightly opened. The fuel from When the choke cable (1) is activated, the starter plunger float chamber (2) is metered by pilot jet (3) where it mixes (5) is lifted off the seat. with air coming in through pilot air jet (4). The mixture then goes up through pilot passage to pilot screw (5).

  • Page 93: Main System, Float System

    Consequently the vacuum slide (2) moves upward. The inlet needle seat (4), and around the inlet needle (2). As fuel in float chamber (3) is metered by main jet (4), and the fuel fills the float chamber, the float (1) rises and...

  • Page 94: Pilot Screw, Air/fuel Mixture Ratio

    100% Throttle Valve Opening Pilot Screw Location A carburetor with a slide type throttle valve is also called a variable venturi type carburetor. In this type of carburetor, the needle jet and jet needle serve to control proper air/ fuel mixture ratio at the medium throttle valve opening (between 1/4 and 3/4 opening).

  • Page 95: Needle Jet, Jet Needle, Throttle Opening Vs. Fuel Flow

    This middle of the needle to the lower end. The top is fixed to air initiates the mixing and atomizing process inside the the center of the throttle valve by the needle clip, and the needle jet.

  • Page 96: Carburetor Disassembly – Mikuni Cv

    CARBURETOR DISASSEMBLY – MIKUNI CV plate, and carefully remove needle seat. NOTE: Do Use the following disassembly, assembly, and inspection not use a pliers to remove the seat or permanent techniques to service a CV carburetor. damage may occur. 1. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver.

  • Page 97: Carburetor Cleaning, Carburetor Inspection

    To check, slide a slightly larger new jet diately. needle into the needle jet and hold it to a light source. Carburetor cleaners can be extremely caustic. Ex- Light will be visible between the needle and needle jet tended periods of soaking can loosen the adhesive if it is worn.

  • Page 98: Carburetor Assembly, Float Height Adjustment

    2. Be sure the tab (E) on outer edge of diaphragm is The bottom of the float should be parallel with the float positioned properly in the carburetor body.

  • Page 99: Fuel Level Test, Needle And Seat Leakage Test

    FUEL LEVEL TEST 3. Measure the height from the float bowl mating surface to the top of step of the float as shown in Illustration 2. A fuel level test can be performed on some models if the Both sides of float should be parallel to each other.

  • Page 100

    • Worn jet needle/needle jet • Float level too low • Plugged or restricted idle jet • Intake air leak ( throttle shaft, intake ducts, airbox or air cleaner cover) Erratic Idle • Jet needle position incorrect • Choke cable bending or incorrectly adjusted •...

  • Page 101: Air Intake System

    - - FUEL SYSTEM / CARBURETION AIR INTAKE SYSTEM Air Intake System Table 4-4: Air Intake System Reference Description Reference Description Pre-Filter Crankcase Breather Hose Air Filter Intake Box Snorkel Intake Box Cover Cover Seal Crankcase Breather Foam Intake Box Drains Carburetor Snorkel 4.17...

  • Page 102: Fuel Tank/fuel Delivery System, Fuel Tank / Fuel Delivery System

    Fuel Pump Fuel Level Gauge Hose (Fuel Pump-To-Carburetor) Fuel Tank Vent Hose (Fuel Pump-To-Carburetor Vacuum Impulse) Fuel Filter (Arrow points in direction of fuel flow to Fuel Tank Hold-Down Bracket / Pad carburetor.) Fuel Tank Fuel Supply Petcock Hose (Supply Petcock-To-Fuel Pump)

  • Page 103: Exhaust System

    - - FUEL SYSTEM / CARBURETION EXHAUST SYSTEM Exhaust System Table 4-6: Exhaust System Reference Description Tip / Spark Arrestor Muffler Pipe Clamp Gasket Head Pipe Flange Gasket 4.19...

  • Page 104


  • Page 105: Table Of Contents


  • Page 106

    NOTE: The outside insert (B) should be flush Removal / Installation surface after installation. Some Polaris ATVs use a two piece plastic insert in place of a metal screw. The plastic inserts are simple to remove and install. Use a a pair of diagonal side cutters to lift the plastic insert (A) until you feel some slight pressure or lift the insert approximately 1/4"...

  • Page 107

    BODY AND STEERING FRONT CAB/FENDER seat. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel. Pull the panel downward and rearward to remove it from the ATV.

  • Page 108: Front Cab/fender Removal, Front Cab/fender Instalation

    Remove the fuel tank cover (4). Remove the side panels (1,3). Remove the plastic rivets on the mud guards (below) and remove them from the front cab assembly. Remove the battery connections (negative first). Remove the battery from the battery compartment.

  • Page 109: Body Assembly, Footwell Removal/installation, Rear Cab Removal/installation

    Remove the screws (1,19) that secure the rear cab to the Exploded View frame. Remove the plastic inserts (9) that secure the rear cab to the frame footwells (11,14). Disconnect the rear lights. Lift the rear cab (4) from the frame.

  • Page 110: Body Rack Exploded View

    - - BODY AND STEERING BODY RACK EXPLODED VIEW REAR RACK REMOVAL/INSTALLATION Remove the fasteners 2,3,7,9,10 and 11. Remove the rear rack. Replace in reverse order.

  • Page 111


  • Page 112: Pod/key Switch/choke/speedo Connection Removal/installation, Handlebar Removal

    Remove the plastic dart clips(1) from the pod (2). Press the center and pull the speedo connection away from the speedo (3). Remove the key switch connection by turning the ignition nut (9) counter clock wise. Remove the choke connection by turing the choke nut (14) counterclockwise.

  • Page 113: Handlebar Installation

    Replace the handlebar assembly into the steering post to the desired angle. Place the handlebar block onto the steering post. Make sure that the peg (C) is inserted to the steering post dimple (D). Insert the bolts through the top of the handlebar block.

  • Page 114: Steering Post Removal

    “HANDLEBAR REMOVAL” on page 5.8. Remove the fuel tank bracket (A). 10. Remove the steering post bracket (F) at the front gear case (4x4 shown)/plate (2x4). Turn the fuel valve to the “OFF” position Remove the fuel line (B) from the fuel pump (C).

  • Page 115: Steering Post Bearing Replacement, Steering Post Installation

    NOTE: Make sure that the cotter pin is not obstructing steering movement. Place the tie rod retainer (H) on to a tie rod bolt (I). Insert the tie rod bolts from the bottom of the tie rod, and line up the retainer to the bottom of the tie rods.

  • Page 116: Steering / A-arm

    12. Tighten the fuel tank bracket fasteners. 13. Hook up the fuel line to the fuel pump and move the clamp to the correct area. NOTE: To avoid damage to tie rods and other steering components, be sure to install tie rod end bolts in the proper direction.

  • Page 117: A-arm Removal, A-arm Assembly

    Insert the ball joint (13) far enough into the carrier bearing assembly so that the pinch bolt (10) can be inserted. Insert the pinch bolt (10) so that the flange head is at the front of the machine and the flange nut (9) is at the rear.

  • Page 118: Front Strut Removal, Front Strut Installation, Bearing Replacement

    Remove the wheel on the side of the strut that is to be replaced. Remove the front cab. With an open end wrench hold the shock tower nut (16) and with a socket turn the shock rod. Remove the screw that holds on the brake line to the strut.

  • Page 119

    Remove the snap ring (1) from the ball joint. Press out the old ball joint (2). Press in new ball joint into A-Arm. Replace the snap ring (1) onto the new ball joint. Assemble the A-Arm, See “A-ARM ASSEMBLY” on page 5.13.

  • Page 120: Upper And Lower Rear Control Arm Removal/installation

    (1,3) fasteners and pivot shaft locations. Remove the x short grey bushings (2) and pivot shafts (3,14). Remove the Lower Control Arm (LCA) (11) fasteners (4,5,12) from the frame and bearing carrier. Note the long (5,8) and short (12,14) fasteners and pivot shaft locations.

  • Page 121

    - - BODY AND STEERING 5.17...

  • Page 122

    - - BODY AND STEERING 5.18...

  • Page 123

    - - BODY AND STEERING 5.19...

  • Page 124


  • Page 125: Table Of Contents


  • Page 126: Brakes / Torque

    Brake Line Flare Fittings 12-15 16-21 Bleeder Screw (36-46 in.lbs.) NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are used when torquing certain bolts and fasteners. Do not re-use fasteners that have pre-applied locking agents.

  • Page 127: Brake Noise

    TROUBLESHOOTING Brake Noise Possible Cause Remedy Dirt or dust buildup on the brake pads and disc is the most If noise does not change common cause of brake noise (squeal caused by vibration). If Noise is from other source when brake is applied cleaning does not reduce the occurrence of brake noise, a ™...

  • Page 128: Brake System Main Components

    - - BRAKES BRAKE SYSTEM MAIN COMPONENTS System Exploded View 2 screws - 7 in. lbs. (.79Nm ) All Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm) All Bleed Screws: 36-46 in.lbs. (4-5 Nm) Apply a Light Amount of Pipe Sealant to Threads All Banjo Style Fittings: 15 ft.lbs.

  • Page 129: Exploded View, Brake Caliper, Hydraulic Brake System

    - - BRAKES BRAKE CALIPER Exploded View A.Bleeder Screw B. Caliper Body C. Internal Caliper Slide Pin O-rings (small) D. Square Seals E. Piston F. Caliper Mount G. Brake Pads H. Internal Caliper Slide Pin O-rings (large) I. Caliper mount O-ring...

  • Page 130: Operation Overview

    Never overfill the reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of the cylinder. The Polaris disc brake system consists of the following This system also incorporates a diaphragm (E) as part of the components or assemblies: hand brake lever;...

  • Page 131: Rear Master Cylinder, Fluid Change

    Operation Overview CAUTION Brake Fluid Reservoir Use only DOT 3 or 4 brake fluid as an assembly aid for all procedures described in this chapter to prevent brake system contamination. DO NOT USE LUBRICANTS OF ANY KIND FOR ASSEMBLY, AS THEIR USE CAN CAUSE RUBBER COMPONENTS TO SWELL.

  • Page 132

    Attach a clean, clear hose to fitting allow the reservoir to drain completely. Continue this and place the other end in a container. Be sure the hose fits process at each bleeder until the fluid runs clear.

  • Page 133: Hand Brake Master Cylinder

    Install diaphragm, cover and screws. Align any marks (if present) into the proper holes in the master cylinder. CYLINDER Wiggle and press down on the cap to be sure it fits evenly and snug. Torque the screw to 7 in.lbs. (0.79 Nm). Removal Clean master cylinder and reservoir assembly.

  • Page 134

    Banjo Bolt Install master cylinder on handlebars. Torque mounting bolts to 70 in. lbs. (7.9 Nm). Torque the inside bolt first as indicated in the illustration to the right. 7 in.lbs. (.79 Nm) Brake Line Torque Bolt First Fill reservoir with DOT3 or DOT 4 brake fluid.

  • Page 135: Brake Pads

    Loosen the wheel nuts. Elevate and support front of machine and remove the tire(s). CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. Remove caliper from mounting bracket.

  • Page 136: Front Caliper

    (30 Nm) Slowly pump the brake lever until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. Compress mounting bracket. Install pads with friction Verify fluid level in reservoir is up to MAX line inside material facing each other.

  • Page 137

    Use caution the piston square seals using a wooden or plastic pick. Use not to bend or damage the retainer or the brake pad ears. caution not to scratch or damage the piston or the bore of the caliper.

  • Page 138

    O-rings for reassembly. Clean the Inspect caliper body for nicks, scratches or wear. Measure caliper body, piston, and retaining bracket with brake bore size and check for out of round. Replace if damage is cleaner or alcohol. evident or if worn.

  • Page 139

    Install new piston square seals (A) in the caliper body (B). Clean the disc and pads with brake parts cleaner or Be sure groove is clean and free of residue or brakes may denatured alcohol to remove any dirt, oil or grease.

  • Page 140: Brake Burnishing Procedure, Brake Disc, Thickness / Runout Inspection, Wear Inspection

    Start machine and slowly increase speed to 30 m.p.h.. Gradually apply brakes to stop machine. Allow pads and disc to cool sufficiently after each stop during the procedure. Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times. BRAKE DISC...

  • Page 141

    FOOT BRAKE removing the brake disc mounting bolts before applying heat to the bolts. Apply heat to the hub in the area of the brake disc Foot Pedal Removal / Install mounting bolts to soften the bolt locking agent. Remove the cotter key (A).

  • Page 142: Foot Brake Master Cylinder Removal / Installation

    Replace parts as needed. To install the rear brake master cylinder, mount the master LEVER VIBRATION cylinder to the mount plate and torque bolts to 8 ft.lbs. (11 Nm). • Disc damaged Reinstall the brake line and torque the banjo bolt (with •...

  • Page 143: Table Of Contents


  • Page 144

    Serious injury could occur if machine tips or falls. equipped with (aluminum or steel wheel) when torquing wheel nuts. Remove wheels. Remove cotter pin and nut from lower A-arm ball joint. Table 7-1: Torque Table Remove lower A-arm from ball joint using a suitable tool. ft.lbs.

  • Page 145

    - - FINAL DRIVE CV BOOT SERVICE Pull sharply or use a pry bar to remove CV shaft from the gearcase. Inspection Check the front and rear driveshaft CV boots for signs of cracking, tearing, punctures or leaking grease. If the driveshaft boot loses all of the grease, CV joint failure will occur.

  • Page 146

    This will allow the air pressure to equalize in the necessary. Front drive axle CV boot replacement CV boot in the position that the joint will spend most of its requires 4 oz. of grease. life. Before you remove the instrument, verify the small end of the boot is in its correct location on the axle.

  • Page 147: Front Hub Bearing (2x4/4x), Front Prop Shaft

    Remove outer snap ring. Press bearing into place until outer race bottoms on housing. CAUTION When using an arbor press be sure to press only on the outer race, as bearing damage may occur. Install snap ring into groove. FRONT PROP SHAFT...

  • Page 148

    Always wear eye protection! Remove internal or external snap ring from all bearing caps. Force U-joint cross to one side and lift out of inner yoke. NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting and mark inner and outer yoke for correct re- positioning during installation.

  • Page 149

    Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. Using a suitable arbor, fully seat bearing cap in one side. Continually check for free movement of bearing cross as bearing caps. Using a suitable arbor, fully seat bearing cap in one side.

  • Page 150: Awd Front Drive Axle Exploded View

    - - FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW Front Drive Shafts and Propshafts NOTE: Refer to your parts manual for the proper replacement parts. Drive Axle Components Outer CV Joint Inner Boot Inner CV Joint Outer Boot...

  • Page 151: Front Gearcase - Centralized Hilliard

    - - FINAL DRIVE FRONT GEARCASE - to the output hubs that link both front axles, resulting in True All Wheel Drive. CENTRALIZED HILLIARD Operation Overview Roller Cage & Bearings Ring Gear Engaging Front Gearcase: The AWD switch may be turned on or off while the vehicle is moving.

  • Page 152: Front Gearcase


  • Page 153

    Elevate machine until the front wheels are off the ground and support machine under footrest/frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service proce- dure. Wear eye protection when removing and installing bearings and seals.

  • Page 154

    Remove the front gearcase from either side of frame. Front Gearcase Removal Remove 4 Bolts 13. Pull the strut assembly out and pull the drive-shaft out of the hub. (Hubs removed for clarity - removal not required) DISASSEMBLY Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet.

  • Page 155

    - - FINAL DRIVE Remove ring gear and roller assembly. Remove the ring gear, roll cage assembly, rollers, and H- springs from the gearcase. Clean all parts and inspect for wear. Inspect ring gear backlash pad (arrow) for wear or damage.

  • Page 156

    13. Inspect the armature plate (E) for a consistent wear pattern. Uneven wear of the armature plate surface (E) indicates a warped plate, which may cause intermittent operation. 11. Inspect the output hub thrust bearing. Replace if wear or damage is found. 7.14...

  • Page 157

    Replace case half needed. Clean the inside surfaces of both gearcase halves. if coil is found to be non-functional or if the coil surface is damaged. 17. Remove and replace the O-rings and seals (arrows) from the gearcase halve assemblies.

  • Page 158

    Install the output hub (A) into the gearcase housing. Apply Install the ring gear over the output hub and into the output a small amount of grease to the seal and seal surface as this cover. Insert the backlash pad (G) and set assembly will aid assembly.

  • Page 159: Awd Diagnostics: Awd Will Not Engage

    Inspect the armature plate for a consistent wear pattern. There should one or two distinct wear bands (one band inside the other). If only one band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4.

  • Page 160

    The top of the coil should be seated below the U-shaped insert. The U-shaped insert controls the pole gap. If the top of the coil is above the surface of the U-shaped insert it raises the armature plate, thereby increasing pole gap.

  • Page 161

    Remove wheel nuts and wheel. drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information. Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire. (Left side only) 7.19...

  • Page 162

    - - FINAL DRIVE Remove hub nut, domed washer and flat washer. 11. Remove both lower control arm bolts. Remove hub. 12. Remove bearing carrier. Disassembly Remove outer snap ring. 10. Remove upper control arm bolt as shown. 7.20...

  • Page 163: Rear Hub Assembly

    - - FINAL DRIVE From the back side, tap on the outer bearing race with a Start bearing in housing. drift punch in the reliefs as shown. Press bearing into place until outer race bottoms on NOTE: Drive bearing out evenly by tapping on outer housing.

  • Page 164: Drive Shaft And Cv Joint, Handling Tips

    Install cone washers with domed side facing outward. Install retainer nut, wheel and wheel nuts. Remove jackstand and torque axle nut and wheel nuts. Install a new cotter pin. Tighten nut slightly to align holes if required. DRIVE SHAFT AND CV JOINT...

  • Page 165: Rear Cv Shaft

    • Do not allow boots to come into contact with sharp edges or hot engine and exhaust components. • Shafts should never be used as a lever arm to position other suspension components. • Never use a hammer or sharp tools to remove or to install boot clamps.

  • Page 166: Cv Joint Service, Cv Joint Replacement

    Clamp Pliers (PN 8700226) (A). Tap CV housing off shaft Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown. NOTE: Photo below is shown without shaft for clarity. Wipe grease away from recess in CV joint...

  • Page 167: Removal And Cleaning

    Install a new boot onto the axle shaft and fill the CV joint and boot with the correct type and amount of grease.

  • Page 168

    This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of the boot is in its correct location on the axle.

  • Page 169: Table Of Contents


  • Page 170

    - - CVT TRANSMISSION TORQUE SPECIFICATIONS CVT TORQUE SPECIFICATIONS 96 in. lbs. (10.8 Nm) 185 ft. lbs (250 Nm) Use Clutch Holder PA-47478 14 ft. lbs. (19 Nm) Clamps - 25 in. lbs.

  • Page 171: Gear Selection

    SPECIAL TOOLS SHIFT LINKAGE INSPECTION SPECIAL TOOLS NOTE: Shift rod is preset at time of manufacture. 1. Inspect shift linkage rod bushing clips and replace if worn or damaged. Lubrication of rod ends is not required. GEAR SELECTOR REMOVAL 1. Push linkage rod out of bushing clip to remove.

  • Page 172: Cvt Operation, Cvt Operation Overview, Drive Clutch Operation, Driven Clutch Operation, Starting Clutch Operation

    CVT system. The starting clutch is located on the left (CVT) side of the Engine power is sensed by the driven clutch via the drive engine crankshaft.

  • Page 173: Cvt Drying, Engine Braking Clutch, Cvt Maintenance/inspection

    CVT cover, remove the CVT drain plug located on the downhill) and throttle settings are constant, the drive and bottom of the CVT cover and let the water drain out. driven clutches upshift or backshift accordingly to (The location of the CVT drain plug is shown on the maintain optimum engine RPM.

  • Page 174: Cvt Overheating/diagnosis

    Clamps CVT OVERHEATING/DIAGNOSIS During routine maintenance or whenever CVT system overheating is evident, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase CVT system operating temperatures. The ATV should be operated in LOW RANGE (if equipped) when pulling or plowing heavy loads, or if extended low speed operation is anticipated.

  • Page 175

    Warm engine at least 5 min., then with transmission in neutral, advance low ambient temperatures. throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning. Slow and easy clutch engagement.

  • Page 176: Cvt System Disassembly / Drive Clutch

    Rotate the inner race to be sure it rotates freely without binding after installation. 5. Install the snap ring. Be sure it is fully seated in the groove. 8. Separate driven clutch sheaves and force belt down Cover Bearing into the sheaves.

  • Page 177

    10. Remove the primary sliding sheave and cam plate assembly as one assembly. Inspect the movable sheave for scoring, grooving, or abnormal wear. NOTE: If tool is not installed, be sure to hold cam plate and primary sliding sheave together to prevent Cam Plate Bushing rollers from falling out of the assembly.

  • Page 178: Cvt System / Driven Clutch Service

    Do not apply any lubricants balance. to the components. Apply Loctite 242 (Blue) to threads and torque the retaining nut to 185 ft. lbs. (250 X mark Nm). IMPORTANT: Be sure splines of cam plate are fully...

  • Page 179

    Standard Length: damaged. 7.52” (191.1 mm) 15. Apply a light film of moly grease to seal lips and to the inside of the roller pin hub. Install the moveable 9. Carefully pry up the roller cover to remove it. Inspect sheave over the shaft of the fixed sheave until the sheaves contact each other.

  • Page 180

    The surface of the pins must be and install nut hand tight. approximately flush with the surface of the roller pin 31. Release the tool and torque the nut to 45 ft lbs (61 hub. Nm) using the same tools for removal of the nut.

  • Page 181

    - - CVT TRANSMISSION TRANSMISSION 18 ft. lbs. (24.5 Nm) 8.13...

  • Page 182: Transmission Service, Transmission Disassembly

    8. Inspect all bearings, gear teeth, and splines for wear or damage. Inspect gear dogs carefully and replace if the edge of the dog is worn or rounded, chipped, or broken. 9. Inspect the reverse chain for damage.

  • Page 183

    - - CVT TRANSMISSION 10. Gear dogs should be square at the corners. Replace 13. Reassemble the drum starting with shaft guide, detent both mating gears if any are rounded. cam (wide flange faces toward the threaded end of drum), the flat washer, and snap ring.

  • Page 184

    17. Assemble the shafts with chain and shift drum and fork, small spring, and shaft support onto the shaft. install the assembly into the case. The dot on the shaft support faces away from the fork. Shaft Support Shaft Support...

  • Page 185

    19. Apply 3-Bond 1215 sealant evenly to clean and oil- free case sealing surfaces. 20. Install the left case and tap it into place until seated. 21. Install bolts and torque in two steps following a cross pattern to 18 ft. lbs. (24.5 Nm).

  • Page 186


  • Page 187: Table Of Contents

    ALTERNATOR OUTPUT TEST (AC AMP)........9.18...

  • Page 188: Electrical Service Notes

    A fusible link is installed on the battery voltage circuit that supplies power to the main 15A fuse. The link is located at the • Become familiar with the operation of your meter. Be starter motor solenoid + post.

  • Page 189: Gear Position Switch, Rpm Limit Modes

    RPM to approximately Move the gear selector handle to each of the three drive 3500 RPM when the transmission is in reverse. positions (FWD, NEU, or REV). • Maximum engine RPM is reached.

  • Page 190: Instrument Gauge Power / Fwd / Neutral Switches / Rpm Signal

    The instrument gauge determines engine RPM from the Y/RED AC signal from the voltage regulator. The gauge is powered by switched R/BLK and switched R/WHT battery voltage. Both the key and the RUN switches have to be closed to power-up the gauge.

  • Page 191: Vehicle Speed Sensor

    To test the circuit: forth across the face of the sensor while monitoring the multimeter. Turn the ignition key to the ON position and move the RUN/OFF switch to run. The multimeter display should flip between a voltage and 0vDC every time the screwdriver blade passes by the Verify there is battery voltage present on the ORANGE sensor face.

  • Page 192: Awd Control System

    AWD Control System Battery voltage is supplied to the AWD coil when the operator turns the key switch to RUN, moves the AWD switch to AWD The front differential coil is controlled by the speedometer the and moves the RUN/OFF switch to RUN.

  • Page 193: Etc / Reverse Rpm Control System

    If the ETC switch connects to ground, the instrument gauge will shut the engine off. The operator can override the RPM speed limit in reverse, but not the ETC RPM limit, by pressing and holding the reverse override button located on the left handlebar.

  • Page 194: Charging System

    - - ELECTRICAL Charging System The charging system consists of:. • Stator • Battery • Regulator / Rectifier The regulator / rectifier is responsible for converting AC voltage to DC voltage, and generating the tachometer pulse.

  • Page 195: Ignition System

    - - ELECTRICAL Ignition System The ignition system consists of:. • CDI Controller • Battery • Ignition Coil • Stator - Pulse Coil • ETC / Key / Run-Off Switches / Instrument Gauge...

  • Page 196: Starting System

    - - ELECTRICAL Starting System The starting system consists of:. • Battery • Key Switch / Run-Off Switch • Solenoid • Brake / Neutral Switches - Diodes • Starter Motor 9.10...

  • Page 197: Ignition Coil Testing, Stator Function Test

    TEST 1: Resistance Value of Each Stator Leg Measure the resistance value of each of the three stator legs: W1 to W2, W1 to W3, and W2 to W3. Each should measure 0.314ohms. Measure each of the white wires to ground, the reading should be (O.L.).

  • Page 198: Cdi Cranking Output Test

    VOLTMETER output from each component. A peak reading voltmeter can be used to perform the tests. A variety of peak reading adaptors are Re-connect all CDI wires to stator wires. Disconnect CDI commercially available for use with the Fluke™ 77 Digital module wire from ignition coil primary terminal.

  • Page 199

    CONTROL (ETC) SWITCH Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean The Electronic Throttle Control (ETC) switch is designed to and tight. Also be sure that colors match when wires are close in the event where the throttle cable sticks or breaks.

  • Page 200: Ignition System Troubleshooting

    Cap removed - 3,200Ω Are these values within specs? If all of the above tests are within specifications, and all grounds, connections, and wire color coding have been inspected, perform voltage output tests on following page or replace the CDI module.

  • Page 201

    - - ELECTRICAL • Fouled spark plug • Faulty spark plug cap or poor connection to high tension lead • Related wiring loose, disconnected, shorted, or corroded • Engine Stop switch or ignition switch faulty • ETC switch misadjusted or faulty •...

  • Page 202: Charging System Testing

    - - ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system checks: Remove the battery and properly ser- Using a multitester set on D.C. volts, mea- vice. Reinstall the fully charged battery sure the battery open circuit voltage (see or a fully charged shop battery.

  • Page 203: Current Draw - Key Off, Charging System "break Even" Test

    Connect an ammeter in series with the negative battery cable. Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate the draw.

  • Page 204: Battery Identification

    • Maximum alternator output will be indicated on the meter. It is not necessary to increase engine RPM above idle. • Place the red lead on the tester in the 10A jack. • Turn the selector dial to the AC amps (A ) position.

  • Page 205: Conventional Battery Activation/ Svc

    Charge battery at 1/10 of its amp/hour rating. Examples: 1/ acid. Serious burns can result from contact with 10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4 skin, eyes or clothing. Antidote: amp; 1/10 of 18 amp battery = 1.8 amp (recommended charging rates).

  • Page 206: Conventional Battery Inspection/removal, Conventional Battery Installation, Conventional Battery Testing

    Whenever removing or reinstalling the battery, dis- connect the negative (black) cable first and reinstall Following are three tests which can easily be made on a battery the negative cable last! to determine its condition: OCV Test, Specific Gravity Test and Load Test.

  • Page 207: Conventional Battery Specific Gravity Test, Conventional Battery Load Test

    As the battery goes through the charge/discharge cycle, the electrolyte 100% Charged 1.265 1.275 goes from a heavy (more acidic) state at full charge to a light (more water) state when discharged. The hydrometer can 75% Charged 1.210 1.225...

  • Page 208: Conventional Battery Charging Procedure

    • Using a wire brush or knife, remove any corrosion from the cables and terminals. (PN 2871329) • Make sure that the electrolyte is at the proper level. Add distilled water if necessary. Connect battery cables. • Charge at a rate no greater than 1/10 of the battery’s WARNING amp/hr capacity until the electrolyte’s specific gravity...

  • Page 209: Starter System Testing Flow Chart

    ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- Remove battery and properly service.

  • Page 210: Starter Motor Exploded View


  • Page 211: Starter System, Removal / Disassembly, Voltage Drop

    - - ELECTRICAL STARTER SYSTEM To perform the test, place the meter on DC volts and place the meter leads across the connection to be tested. Refer to the chart on 1.47 to perform voltage drop tests on the starter Troubleshooting system.

  • Page 212: Inspection & Replacement

    O-rings located on the armature housing. O-Rings Shims Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. Slide brush end frame off end of starter. NOTE: The shims will be replaced during NOTE: The electrical input post must stay with the reassembly.

  • Page 213: Reassembly & Installation

    Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no continuity). Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. CAUTION Some cleaning solvents may damage the insulation in the starter.

  • Page 214: Starter Solenoid, Bench Testing

    Install O-ring, two small phenolic spacers, large phenolic washer, flat washer, lock washer, and terminal nut. 10. Install the starter onto the engine case. Hand tighten each of the starter bolts. Torque the bottom bolt first to 9 ft.lbs. While holding brush springs away from brushes, push (12 Nm).

  • Page 215: Starter Drive, Pinion Gear - Anti-kick Out Shoe, Garter Spring Replacement

    Screw the overrun clutch out to the engaged position on the pinion shaft assembly. Use a small piece of wire with the end bent in a hook and pick the old spring out of its channel. Slide it off the end of the shaft. Slide the new spring over the overrun clutch and into the spring groove.

  • Page 216

    - - ELECTRICAL NOTES 9.30...

  • Page 217

    - - WIRE DIAGRAM 2006 HAWKEYE 2X4/ 4X4 10.1...

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