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Polaris Service Repair Manual Atv Hawkeye 300 2×4 4×4 2000-2009 – PDF Download
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Polaris Service Repair Manual Atv Hawkeye 300 2×4 4×4 2000-2009
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Description
Polaris Service Repair Manual Atv Hawkeye 300 2×4 4×4 2000-2009
FILE DETAILS:
Polaris Service Repair Manual Atv Hawkeye 300 2×4 4×4 2000-2009
LANGUAGE:ENGLISH
PAGES:217
DOWNLOADABLE:YES
FILE TYPE:PDF
POLARIS SERVICE REPAIR MANUAL ATV HAWKEYE 300 2X4 4X4 2000-2009 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
SAMPLE PAGE FROM THE MANUAL:
Polaris Service Repair Manual Atv Hawkeye 300 2×4 4×4 2000-2009
Apply clean engine oil to all ring surfaces and ring lands. Always check piston ring installed gap before rings are installed on piston. If the piston has been in service, clean any accumulated carbon from the ring grooves and oil control ring holes.
1. Place the oil control ring expander in oil ring groove with the end gap facing forward. The expander has no up or down marking and can be installed either way. The ends should butt squarely together and must not overlap.
2. Install the oil ring top rail with the end gap at least 30o from the end of the expander.
3. Install the bottom rail with the gap at least 30o from the end of the expander on the side opposite the top rail gap.
4. Install the second ring with the mark facing up. The second ring has an undercut with a tapered face. Position the end gap toward the rear (intake) side of the piston.
5. Install the top ring with the marking facing up. The top ring has an inner bevel with a barrel face
TABLE OF CONTENTS:
Polaris Service Repair Manual Atv Hawkeye 300 2×4 4×4 2000-2009
GENERAL INFORMATION........................................................... 1 VEHICLE IDENTIFICATION.................................................... 2 Model Identification.................................................. 2 Engine Designation Number............................................. 2 Vehicle Identification Number (VIN)................................... 2 Vehicle and Engine Serial Number Locations............................ 2 SPECIFICATIONS............................................................ 3 MODEL: 2006 HAWKEYE 2x4............................................... 3 MODEL: 2006 HAWKEYE 4x4............................................... 3 MODEL: 2006 HAWKEYE 2x4............................................... 4 MODEL: 2006 HAWKEYE 4x4............................................... 5 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 MAINTENANCE................................................................... 13 MAINTENANCE............................................................... 14 Periodic maintenance chart............................................ 14 Maintenance Chart Key................................................. 14 MAINTENANCE AND LUBRICATION........................................... 15 LUBRICANTS / FLUIDS....................................................... 18 POLARIS LUBES/FLUIDS.................................................. 18 Polaris Lubricants,Maintenance and service Products................... 19 Polaris Lubricant symbol Identification............................... 20 VEHICLE INSPECTION / MAINTENANCE.......................................... 20 PRE-RIDE / DAILY INSPECTION........................................... 20 HAWKEYE HANDLEBAR Component locations................................. 21 Maintenance quick reference........................................... 21 Transmission Lubrication.............................................. 23 FRONT GEARCASE Lubrication (4X4 ONLY)................................. 23 Lubrication / Grease points........................................... 24 Throttle Operation - All Models....................................... 24 CHOKE (ENRICHER) ADJUSTMENT........................................... 24 CARBURETOR DRAINING................................................... 24 Pilot Screw........................................................... 25 Pilot screw adjustment................................................ 25 ELECTRONIC THROTTLE CONTROL (ETC SWITCH)/THROTTLE CABLE ADJUSTMENT.... 26 FUEL SYSTEM........................................................... 26 FUEL LINES............................................................ 26 VENT LINES............................................................ 26 Fuel Filter........................................................... 26 COMPRESSION TEST...................................................... 27 Engine Mounts......................................................... 27 Engine Fastener Torque ............................................... 27 BATTERY MAINTENANCE................................................... 27 Spark Plug............................................................ 28 IGNITION TIMING....................................................... 29 main air filter cleaning.............................................. 29 Air Filter/Pre-filter Service......................................... 29 Air Box Sediment Tube................................................. 30 CVT Drain Plug & Drying............................................... 30 engine oil level...................................................... 30 OIL AND FILTEr CHANGE................................................. 31 Valve Clearance Adjustment............................................ 32 Steering.............................................................. 32 Tie RoD End/Steering Inspection ...................................... 33 Camber and Caster..................................................... 33 Toe alignment......................................................... 33 Toe Alignment Adjustment.............................................. 34 Exhaust cleaning...................................................... 34 Brake System Inspection............................................... 35 Brake Pad Inspection.................................................. 35 Hose/Fitting Inspection............................................... 35 Brake freePlay........................................................ 35 Suspension Spring FRONT / REAR Preload Adjustment..................... 36 Front Suspension INspection........................................... 37 Rear Suspension Inspection............................................ 37 controls.............................................................. 37 Wheels................................................................ 37 WHEEL, HUB, AND SPINDLE TORQUE TABLE.................................. 37 Wheel Removal/Install- Front or Rear.................................. 37 Wheel Installation.................................................... 38 Tire PressurE......................................................... 38 Tire Inspection....................................................... 38 Frame, Nuts, Bolts, Fasteners......................................... 38 ENGINE........................................................................ 39 TOOLS..................................................................... 41 Special Tools......................................................... 41 TORQUE SPECIFICATIONS..................................................... 41 ENGINE Torque Specifications.......................................... 41 Torque Patterns....................................................... 42 GENERAL ENGINE SERVICE.................................................... 43 Engine Exploded View.................................................. 43 Engine Service Data................................................... 44 Engine Service Data................................................... 45 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 CAMSHAFT CHAIN........................................................ 72 BALANCE SHAFT Bearing Inspection...................................... 72 Crankcase Oil PICKUP Strainer Inspection.............................. 72 Bearing /SEal Installation............................................ 72 End Play Inspection/Adjustment........................................ 73 Crankshaft End Play Adjustment........................................ 73 Counter Balancer Shaft End Play Adjust................................ 74 Crankcase reassembly.................................................. 75 CAM CHAIN, OIL PUMP, & Tensioner Blade Installation................... 76 Piston Ring Installation.............................................. 77 Piston Installation................................................... 77 Cylinder Installation................................................. 78 Cylinder Head and camshaft Installation............................... 78 Camshaft INSTALLATION & Timing........................................ 79 Cam Chain Tensioner Installation...................................... 80 ROCKER ARM INSTALLATION............................................... 80 Starter Drive assembly................................................ 81 TROUBLESHOOTING........................................................... 81 Spark Plug Fouling troubleshooting.................................... 81 ENGINE Troubleshooting................................................ 82 FUEL SYSTEM / CARBURETION..................................................... 85 SPECIAL TOOLS............................................................. 86 CARBURETITION............................................................. 87 BST 34 Carburetor Exploded View 1 of 2................................ 87 BST 34 Carburetor Exploded View 2 of 2................................ 88 Carburetor Venting System............................................. 89 Carburetor Specifications............................................. 90 Carburetor Jetting.................................................... 90 Mikuni jet part numbers............................................... 90 CV Carburetor System Function......................................... 90 carburetor venting.................................................... 91 Mikuni CV Carb Operation.............................................. 91 Starter System (Choke or Enrichment).................................. 92 Pilot (Idle and Slow) System ......................................... 92 Main System........................................................... 93 Float System ......................................................... 93 Pilot Screw........................................................... 94 Air/Fuel Mixture Ratio................................................ 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 Needle and Seat Leakage Test.......................................... 99 Fuel Level test....................................................... 99 Troubleshooting.......................................................100 AIR INTAKE SYSTEM.........................................................101 Air Intake System.....................................................101 FUEL TANK/FUEL DELIVERY SYSTEM............................................102 Fuel Tank / Fuel Delivery System......................................102 EXHAUST SYSTEM............................................................103 Exhaust System........................................................103 BODY AND STEERING.............................................................105 PLASTIC INSERT ...........................................................106 Removal / Installation................................................106 SEAT......................................................................106 SEAT REMOVAL/INSTALLATION.............................................106 FRONT CAB/FENDER .........................................................107 FRONT CAB/FENDER REMOVAL..............................................108 FRONT CAB/FENDER INSTALATION..........................................108 B ODY 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 BRAKES........................................................................125 SPECIFICATIONS............................................................126 Brakes / Torque.......................................................126 TROUBLESHOOTING...........................................................127 Brake Noise...........................................................127 BRAKE SYSTEM MAIN COMPONENTS..............................................128 <GRAPHIC>System Exploded View.........................................128 BRAKE CALIPER.............................................................129 Exploded View.........................................................129 HYDRAULIC BRAKE SYSTEM ...................................................129 Operation Overview....................................................130 REAR MASTER CYLINDER......................................................131 Operation Overview....................................................131 BRAKE BLEEDING............................................................131 Fluid Change..........................................................131 Brake Bleeding........................................................132 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 BRAKE SQUEAL..........................................................142 FINAL DRIVE...................................................................143 SPECIFICATIONS............................................................144 Component Torques.....................................................144 FRONT DRIVE CV SHAFT......................................................144 Removal...............................................................144 Installation..........................................................145 CV BOOT SERVICE...........................................................145 Inspection............................................................145 Disassembly...........................................................145 FRONT HUB BEARING (2x4/4x4)...............................................147 Removal...............................................................147 Installation..........................................................147 FRONT PROP SHAFT..........................................................147 Removal...............................................................147 Installation..........................................................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 REAR CV SHAFT.............................................................164 Removal...............................................................164 DRIVE SHAFT AND CV JOINT .................................................164 HANDLING TIPS.........................................................164 REAR CV SHAFT.............................................................165 INSTALLATION..........................................................165 CV JOINT SERVICE..........................................................166 CV Joint Replacement..................................................166 Removal and Cleaning..................................................167 CVT / TRANSMISSION............................................................169 TORQUE SPECIFICATIONS.....................................................170 CVT TORQUE SPECIFICATIONS.............................................170 GEAR SELECTION............................................................171 Shift Linkage Inspection..............................................171 Gear Selector Removal.................................................171 SPECIAL TOOLS.............................................................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 ELECTRICAL....................................................................187 ELECTRICAL SYSTEM.........................................................188 Special Tools.........................................................188 Electrical Service Notes..............................................188 fuse splice saver.....................................................188 Fusible Link..........................................................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 Output Test Using Peak Reading Adaptor OR A VOLTMETER.............198 CDI Cranking Output Test .............................................198 Electronic Throttle Control (ETC) Switch..............................199 Ignition System testing...............................................199 Ignition System Troubleshooting.......................................200 Charging System Testing...............................................202 Current Draw - Key Off................................................203 Charging System “Break Even” Test.....................................203 Alternator Output Test (AC amp).......................................204 Battery identification................................................204 Conventional Battery activation/ SVC..................................205 Battery Terminals/ terminal Bolts.....................................205 Conventional Battery Inspection/Removal...............................206 Conventional Battery Installation.....................................206 Conventional Battery Testing..........................................206 Conventional Battery OCV - Open Circuit Voltage Test..................206 Conventional battery Specific Gravity Test............................207 Conventional battery Load Test........................................207 conventional battery Off- Season Storage..............................208 conventional Battery Charging Procedure...............................208 Starter System Testing Flow chart.....................................209 Starter Motor Exploded View...........................................210 STARTER SYSTEM............................................................211 Troubleshooting.......................................................211 VOLTAGE DROP..............................................................211 Testing...............................................................211 STARTER MOTOR.............................................................211 Removal / Disassembly.................................................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 WIRE_DIAGRAM..................................................................217
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
