Polaris Hawkeye Manuals

Manuals and User Guides for Polaris Hawkeye. We have 1 Polaris Hawkeye manual available for free PDF download: Repair Manual

Polaris Hawkeye Repair Manual

Polaris Hawkeye Repair Manual (217 pages)

Service repair manual

Brand: Polaris | Category: Offroad Vehicle | Size: 10.13 MB

Table of Contents

General Information

1
- Table of Contents
  1
- Chapter 1
  2
- Engine Designation Number
  2
- Model Identification
  2
- Vehicle and Engine Serial Number Locations
  2
- Vehicle Identification
  2
- Vehicle Identification Number (Vin)
  2
- Specifications
  3
- General Information
  6
  - Publication Numbers
    6
  - Replacement Keys
    6
  - Special Tools
    7
  - Standard Torque Specifications
    9
  - Sae Tap Drill Sizes
    10
  - Metric Tap Drill Sizes
    10
  - Decimal Equivalents
    10
  - Conversion Table
    11
  - Glossary of Terms
    12
- Www.instant-Manuals.com - Maintenance Chapter 2 Maintenance

13
- Chapter 2
  14
- Maintenance
  14
- Maintenance Chart Key
  14
- Periodic Maintenance Chart
  14
- Maintenance and Lubrication
  15
- Lubricants / Fluids
  18
- Vehicle Inspection / Maintenance
  20
  - Pre-Ride / Daily Inspection
    20
  - Hawkeye Handlebar Component Locations
    21
  - Maintenance Quick Reference
    21
  - Transmission Lubrication
    23
  - Front Gearcase Lubrication (4X4 Only)
    23
  - Lubrication / Grease Points
    24
  - Throttle Operation - All Models
    24
  - Choke (Enricher) Adjustment
    24
  - Carburetor Draining
    24
  - Pilot Screw
    25
  - Pilot Screw Adjustment
    25
  - Electronic Throttle Control (Etc Switch)/Throttle Cable Adjustment
    26
  - Fuel System
    26
  - Fuel Lines
    26
  - Vent Lines
    26
  - Fuel Filter
    26
  - Compression Test
    27
  - Engine Mounts
    27
  - Engine Fastener Torque
    27
  - Battery Maintenance
    27
  - Spark Plug
    28
  - Ignition Timing
    29
  - Main Air Filter Cleaning
    29
  - Air Filter/Pre-Filter Service
    29
  - Air Box Sediment Tube
    30
  - Cvt Drain Plug & Drying
    30
  - Engine Oil Level
    30
  - Oil and Filter Change
    31
  - Valve Clearance Adjustment
    32
  - Steering
    32
  - Tie Rod End/Steering Inspection
    33
  - Camber and Caster
    33
  - Toe Alignment
    33
  - Toe Alignment Adjustment
    34
  - Exhaust Cleaning
    34
  - Brake System Inspection
    35
  - Brake Pad Inspection
    35
  - Hose/Fitting Inspection
    35
  - Brake Freeplay
    35
  - Suspension Spring Front / Rear Preload Adjustment
    36
  - Front Suspension Inspection
    37
  - Rear Suspension Inspection
    37
  - Controls
    37
  - Wheels
    37
  - Wheel, Hub, and Spindle
    37
  - Torque Table2.25
    37
  - Wheel Removal/Install- Front or Rear
    37
  - Wheel Installation
    38
  - Tire Pressure
    38
  - Tire Inspection
    38
  - Frame, Nuts, Bolts, Fasteners
    38
- Www.instant-Manuals.com - Chapter 3 Engine

39
- Chapter 3 Engine
  41
- Special Tools
  41
- Tools
  41
- Torque Specifications
  41
  - Engine Torque Specifications
    41
  - Torque Patterns
    42
- General Engine Service
  43
  - Engine Exploded View
    43
  - Engine Service Data
    44
  - Oil Flow Diagram
    47
  - Piston Identification
    48
  - Piston Ring Identification
    48
  - Accessible Components
    48
- Engine Service
  48
  - Engine Removal
    48
  - Engine Installation Notes
    51
  - Transmission Removal
    52
  - Transmission Installation Notes
    53
  - Engine Lubrication
    54
  - Oil Flow / Pressure Test
    54
  - Engine Breather / Oil Separator
    54
  - Cam Chain Tensioner Removal
    54
  - Cam Chain Tensioner Inspection
    55
  - Rocker Arm/Shaft Disassembly and Inspection
    55
  - Camshaft Removal and Inspection
    56
  - Camshaft Inspection
    57
  - Cylinder Head Removal
    57
  - Cylinder Head Inspection
    57
  - Cylinder Head Warp Inspection
    58
  - Combustion Chamber Inspection
    58
  - Cylinder Head Disassembly
    58
  - Valve Inspection
    59
  - Valve Seat Reconditioning
    59
  - Cylinder Head Assembly
    62
  - Valve Sealing Test
    62
  - Engine Bottom End Disassembly
    63
  - Cam Chain Guide and Tesioner Blade
    63
  - Piston Removal
    63
  - Cylinder Inspection
    64
  - Cylinder Hone Selection/ Honing Procedure
    64
  - Honing to Deglaze
    64
  - Piston Inspection
    65
  - Piston Ring Installed Gap
    66
  - Flywheel Removal / Inspection
    66
  - Starter Drive Clutch Removal/Inspection
    67
  - Cam Chain Drive Sprocket Removal / Inspection
    67
  - Oil Pump Inspection / Removal
    68
  - Starting Clutch and Engine Braking Clutch Removal /Inspection
    68
  - Starting Clutch Assembly
    69
  - Crankcase Disassembly
    70
  - Crankcase Separation
    70
  - Crankshaft Removal
    71
  - Crankshaft / Cam Chain / Sprocket Inspection
    71
  - Crankcase Oil Passages & Pressure Relief Valve
    72
- Balance Shaft Bearing Inspection
  72
- Bearing /Seal Installation
  72
- Camshaft Chain
  72
- Crankcase Oil Pickup Strainer Inspection
  72
- Crankshaft End Play Adjustment
  73
- End Play Inspection/Adjustment
  73
- Counter Balancer Shaft End Play Adjust
  74
- Crankcase Reassembly
  75
- Cam Chain, Oil Pump, & Tensioner Blade Installation
  76
- Piston Installation
  77
- Piston Ring Installation
  77
- Cylinder Head and Camshaft Installation
  78
- Cylinder Installation
  78
- Camshaft Installation & Timing
  79
- Cam Chain Tensioner Installation
  80
- Rocker Arm Installation
  80
- Spark Plug Fouling Troubleshooting
  81
- Starter Drive Assembly
  81
- Troubleshooting
  81
- Engine Troubleshooting
  82
- Www.instant-Manuals.com - Fuel System / Carburetion Chapter 4 Fuel System / Carburetion

85
- Special Tools
  86
- Bst 34 Carburetor Exploded View 1 of 2
  87
- Carburetition
  87
- Chapter 4
  87
- Bst 34 Carburetor Exploded View 2 of 2
  88
- Carburetor Venting System
  89
- Carburetor Jetting
  90
- Carburetor Specifications
  90
- CV Carburetor System Function
  90
- Mikuni Jet Part Numbers
  90
- Carburetor Venting
  91
- Mikuni CV Carb Operation
  91
- Pilot (Idle and Slow) System
  92
- Starter System (Choke or Enrichment)
  92
- Float System
  93
- Main System
  93
- Air/Fuel Mixture Ratio
  94
- Pilot Screw
  94
- Jet Needle
  95
- Needle Jet
  95
- Throttle Opening Vs. Fuel Flow
  95
- Carburetor Disassembly - Mikuni CV
  96
- Carburetor Cleaning
  97
- Carburetor Inspection
  97
- Carburetor Assembly
  98
- Float Height Adjustment
  98
- Fuel Level Test
  99
- Needle and Seat Leakage Test
  99
- Troubleshooting
  100
- Air Intake System
  101
- Fuel Tank/Fuel Delivery System
  102
- Exhaust System
  103
- Www.instant-Manuals.com - Body and Steering Chapter 5 Body and Steering

105
- Chapter 5 Removal / Installation
  106
- Plastic Insert
  106
- Seat
  106
  - Seat Removal/Installation
    106
- Front Cab/Fender
  107
  - Front Cab/Fender Removal
    108
  - Front Cab/Fender Instalation
    108
- Body Assembly
  109
  - Exploded View
    109
  - Rear Cab Removal/Installation
    109
  - Footwell Removal/Installation
    109
- Body Rack Exploded View
  110
  - Rear Rack Removal/Installation
    110
- Pod Exploded View
  111
  - Pod/Key Switch/Choke/Speedo Connection Removal/Installation
    112
- Steering
  112
  - Handlebar Removal
    112
  - Handlebar Installation
    113
  - Steering Post Removal
    114
  - Steering Post Bearing Replacement
    115
  - Steering Post Installation
    115
- Steering / A-Arm
  116
  - Exploded View
    116
- A-Arm
  117
  - A-Arm Removal
    117
  - A-Arm Assembly
    117
- Front Strut Cartridge Replacement
  117
  - Front Strut Removal
    118
  - Front Strut Installation
    118
  - Bearing Replacement
    118
- Ball Joint
  119
  - Replacement
    119
- Rear Suspension
  119
  - Upper and Lower Rear Control Arm Removal/Installation
    120
- Www.instant-Manuals.com - Brakes Chapter 6 Brakes

125
- Chapter 6 Brakes / Torque
  126
- Specifications
  126
- Troubleshooting
  127
  - Brake Noise
    127
- Brake System Main Components
  128
- Brake Caliper
  129
  - Exploded View
    129
- Hydraulic Brake System
  129
  - Operation Overview
    130
- Brake Bleeding
  131
  - Fluid Change
    131
  - Brake Bleeding
    132
- Rear Master Cylinder
  131
  - Operation Overview
    131
- Hand Brake Master Cylinder
  133
  - Removal
    133
  - Installation
    134
- Brake Pads
  135
  - Removal
    135
  - Installation
    136
- Front Caliper
  136
  - Removal
    136
  - Inspection
    138
  - Reassembly
    139
  - Installation
    139
- Brake Burnishing Procedure
  140
  - Overview
    140
- Brake Disc
  140
  - Thickness / Runout Inspection
    140
  - Wear Inspection
    140
  - Removal / Replacement
    141
- Foot Brake
  141
  - Foot Pedal Removal / Install
    141
  - Foot Brake Master Cylinder Removal / Installation
    142
- Troubleshooting
  142
- Www.instant-Manuals.com - Final Drive Chapter 7 Final Drive

143
- Chapter 7 Component Torques
  144
- Front Drive CV Shaft
  144
  - Removal
    144
  - Installation
    145
- Specifications
  144
- CV Boot Service
  145
  - Inspection
    145
  - Disassembly
    145
- Front Hub Bearing (2X4/4X4)
  147
  - Removal
    147
  - Installation
    147
- Front Prop Shaft
  147
- U-Joint Service
  148
  - Disassembly
    148
  - Assembly
    149
- Awd Front Drive Axle Exploded View
  150
  - Front Drive Shafts and Propshafts
    150
- Front Gearcase - Centralized Hilliard
  151
  - Operation Overview
    151
- Front Gearcase
  152
  - Centralized Hilliard Exploded View
    152
- All Wheel Drive Gearcase
  153
  - Removal
    153
  - Disassembly
    154
  - Reassembly
    157
  - Awd Diagnostics: Awd will Not Engage
    159
  - Installation
    160
- Rear Hub
  161
  - Removal
    161
  - Disassembly
    162
  - Rear Hub Assembly
    163
  - Installation
    163
- Drive Shaft and CV Joint
  164
  - Handling Tips
    164
- Rear CV Shaft
  164
  - Removal
    164
- Rear CV Shaft
  165
  - Installation
    165
- CV Joint Service
  166
  - CV Joint Replacement
    166
  - Removal and Cleaning
    167
- Www.instant-Manuals.com - Cvt Transmission Chapter 8 Cvt / Transmission

169
- Chapter 8 Cvt Torque Specifications
  170
- Torque Specifications
  170
- Gear Selection
  171
  - Shift Linkage Inspection
    171
  - Gear Selector Removal
    171
- Special Tools
  171
- Cvt Operation
  172
  - Cvt Operation Overview
    172
  - Starting Clutch Operation
    172
  - Drive Clutch Operation
    172
  - Driven Clutch Operation
    172
  - Engine Braking Clutch
    173
  - Cvt Maintenance/Inspection
    173
  - Cvt Drying
    173
  - Cvt Overheating/Diagnosis
    174
  - Cvt System Disassembly / Drive Clutch
    176
  - Cvt System / Driven Clutch Service
    178
- Transmission
  181
  - Transmission Service
    182
  - Transmission Disassembly
    182
- Www.instant-Manuals.com - Electrical Chapter 9 Electrical

187
- Chapter 9 Electrical
  188
- Electrical
  188
- Electrical Service Notes
  188
- Electrical System
  188
- Fuse Splice Saver
  188
- Fusible Link
  188
- Special Tools
  188
- Gear Position Switch
  189
- Rpm Limit Modes
  189
- Instrument Gauge Power / Fwd / Neutral Switches / Rpm Signal
  190
- Vehicle Speed Sensor
  191
- Awd Control System
  192
- Etc / Reverse Rpm Control System
  193
- Charging System
  194
- Ignition System
  195
- Starting System
  196
- Ignition Coil Testing
  197
- Stator Function Test
  197
- CDI Cranking Output Test
  198
- CDI Output Test Using Peak Reading Adaptor or Avoltmeter
  198
- Electronic Throttle Control (Etc) Switch
  199
- Ignition System Testing
  199
- Ignition System Troubleshooting
  200
- Charging System Testing
  202
- Charging System "Break Even" Test
  203
- Current Draw - Key off
  203
- Alternator Output Test (Ac Amp)
  204
- Battery Identification
  204
- Battery Terminals/Terminal Bolts
  205
- Conventional Battery Activation/ Svc
  205
- Conventional Battery Inspection/Removal
  206
- Conventional Battery Installation
  206
- Conventional Battery Ocv - Open Circuit Voltage Test
  206
- Conventional Battery Testing
  206
- Conventional Battery Load Test
  207
- Conventional Battery Specific Gravity Test
  207
- Conventional Battery Charging Procedure
  208
- Conventional Battery Off-Season Storage
  208
- Starter System Testing Flow Chart
  209
- Starter Motor Exploded View
  210
- Starter Motor
  211
  - Removal / Disassembly
    211
- Starter System
  211
  - Troubleshooting
    211
- Voltage Drop
  211
  - Testing
    211
- Brushes
  212
  - Inspection & Replacement
    212
- Armature
  213
  - Testing
    213
- Starter
  213
  - Reassembly & Installation
    213
- Starter Solenoid
  214
  - Bench Testing
    214
- Starter Drive
  215
  - Pinion Gear - Anti-Kick out Shoe, Garter Spring Replacement
    215

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