Polaris Hawkeye User Manual

MAINTENANCE
2.15
5. Install clamps on fuel line.
6. Start engine and inspect for leaks.
7. Remove clamps
COMPRESSION TEST
NOTE: This 4-Stroke engine is equipped with an
automatic decompressor. Compression readings will vary
in proportion to cranking speed during the test. Average
compression (measured) is about 90 psi
during a
compression test.
Smooth idle generally indicates good compression. Low engine
compression is rarely a factor in running condition problems
above idle speed. Abnormally high compression can be caused
by a decompressor malfunction, or worn or damaged exhaust
cam lobes. Inspect camshaft and automatic decompression
mechanism if compression is abnormally high.
A cylinder leakage test is the best indication of engine
condition on models with automatic decompression. Follow
tester manufacturer’s instructions to perform a cylinder leakage
test. (Never use high pressure leakage testers as crankshaft
seals may dislodge and leak).
ENGINE MOUNTS
Inspect rubber engine mounts for cracks or damage.
ENGINE FASTENER TORQUE
Check engine fasteners and ensure they are tight
BATTERY MAINTENANCE
NOTE: All Hawkeye batteries are Low Maintenance
design and construction. All Low Maintenance
batteries are fully charged and tested at the factory
before installation. Expected shelf life is 6-8 months
depending on storage conditions. As a general rule
before placing the battery into service, check the
battery condition and charge accordingly.
Low Maintenance batteries are permanently sealed at the time
of manufacture. The use of lead-calcium and AGM technology
instead of lead-antimony allows the battery acid to be fully
absorbed. For this reason, a Low Maintenance battery case is
dark and the cell caps are not removable, since there is no need
to check electrolyte level.
NEVER attempt to add electrolyte or water to a Low
Maintenance battery. Doing so will damage the case and
shorten the life of the battery. Refer to the Battery Maintenance
Video (PN 9917987) for proper instruction on servicing Low
Maintenance batteries.
Cylinder Compression
Standard: 90PSI
Cylinder Leakage
Service Limit: 10%
(Inspect for cause if leakage exceeds 10%)
To Carburetor
Fuel Filter
WARNING
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with
skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Fol-
low with milk of magnesia, beaten egg, or vegetable
oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when charg-
ing or using in an enclosed space. Always shield
eyes when working near batteries. KEEP OUT OF
REACH OF CHILDREN.

Polaris Hawkeye Specifications

General

Brand	Polaris
Model	Hawkeye
Category	Offroad Vehicle
Language	English

Summary

General Information

Vehicle Identification

Information on identifying the vehicle's model, engine, and serial numbers.

Engine

Torque Specifications

Provides torque values for engine components and fasteners.

General Engine Service

Exploded views, service data, and identification of engine components.

Engine Service

Detailed procedures for engine removal, installation, and component service.

Engine Lubrication

Fuel System / Carburetion

Carburettition

Exploded views, components, specifications, and operation of the carburetor.

Brakes

Troubleshooting

Brake System Main Components

Brake Caliper

Hydraulic Brake System

Overview of operation, master cylinder function, and brake bleeding procedures.

Rear Master Cylinder

Brake Bleeding

Step-by-step procedure for bleeding the hydraulic brake system.

Hand Brake Master Cylinder

Brake Pads

Front Caliper

Brake Disc

Foot Brake

Final Drive

Specifications

Component torque specifications and special tools for final drive service.

Front Drive CV Shaft

Procedures for removing, installing, and servicing the front drive CV shaft.

CV Boot Service

Front Hub Bearing (2x4/4x4)

Front Gearcase - Centralized Hilliard

Operation overview and engagement of the centralized Hilliard AWD system.

All Wheel Drive Gearcase

Procedures for removing, disassembling, and reassembling the AWD gearcase.

Rear Hub

Rear CV Shaft

CV Joint Service

CVT / Transmission

Torque Specifications

CVT Operation

CVT Maintenance/Inspection

CVT Overheating/Diagnosis

CVT System Disassembly / Drive Clutch

Steps for disassembling the CVT system and the drive clutch.

CVT System / Driven Clutch Service

Procedures for servicing the driven clutch assembly.

Transmission

Exploded view of the transmission and service overview.

Transmission Service

Procedures for draining fluid and removing the transmission.

Transmission Disassembly

Step-by-step instructions for disassembling the transmission.

Electrical

Electrical System

Charging System

Components and testing procedures for the charging system.

Ignition System

Components and testing procedures for the ignition system.

Starting System

Components and testing procedures for the starting system.

Ignition Coil Testing

Stator Function Test

CDI Output Test Using Peak Reading Adaptor or a Voltmeter

CDI Cranking Output Test

Ignition System Testing

Ignition System Troubleshooting

Diagnostic guide for common ignition system problems and no-spark conditions.

Charging System Testing

Step-by-step checks for diagnosing charging system problems.

Current Draw - Key Off

Charging System "Break Even" Test

Alternator Output Test (AC Amp)

Conventional Battery Testing

Starter System Testing Flow Chart

Diagnostic flowchart for troubleshooting starter motor issues.

Starter System

Troubleshooting guide for starter motor problems and voltage drop testing.

Starter Motor

Procedures for starter motor removal, disassembly, and testing.

Brushes

Armature

Starter

Reassembly and installation of the starter motor.

Starter Solenoid

Starter Drive