2007 Polaris Hawkeye ATV Service & Repair Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 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: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number ES30PFESingle, Air Cooled, SOHC 4 Stroke, Electric Start } Machine Model Number Identification } } Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option A 0 7 LB 2 7 A A }

1.2 GENERAL INFORMATION 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. An additional number is stamped on the center top of the crankcase beneath the cylinder. The machine serial number (1- lower frame rail) and engine number (2- right side engine) are important for vehicle identification. 4 X A L H 2 7 A * 5 P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Descriptor Vehicle Identifier } Check Digit Model Year Body Style Plant No Individual Serial Number * This could be either a number or a letter Powertrain Emissions 1 2

1.3 GENERAL INFORMATION 1 SPECIFICATIONS MODEL: 2007 HAWKEYE 2x4 MODEL NUMBER: . . . . . . . . . A07LB27AA, A07LB27AC A07LB27FA (International) ENGINE MODEL: . . . . . . . . . . ES30PFE MODEL: 2007 HAWKEYE 4x4 MODEL NUMBER: . . . . . . . . . A07LH27AA, A07LH27AB, A07LH27AC, A07LH27AD A07LH27FA (International) ENGINE MODEL: . . . . . . . . . . ES30PFE Category Dimension Length 74 in./188 cm Width 42 in./107 cm Height 45.5 in./116 cm Wheel Base 46 in./117 cm Ground Clearance 8 in./20.3 cm Dry Weight 525 lbs./238 kg Gross Vehicle Weight 930 lbs./422 kg Front Rack Capacity 70 lbs./31.75 kg Rear Rack Capacity 100 lbs./45 kg Towing Capacity 750 lbs./340 kg Hitch Tongue Weight 75 lbs./34 kg Body Style Recreational/Utility Category Dimension Length 74 in./188 cm Width 42 in./107 cm Height 45.5 in./116 cm Wheel Base 46 in./117 cm Ground Clearance 8 in./20.3 cm Dry Weight 550 lbs./250 kg Gross Vehicle Weight 930 lbs./422 kg Front Rack Capacity 70 lbs./31.75 kg Rear Rack Capacity 100 lbs./45 kg Towing Capacity 750 lbs./340 kg Hitch Tongue Weight 75 lbs./34 kg Body Style Recreational/Utility

1.4 GENERAL INFORMATION MODEL: 2007 HAWKEYE 2x4 MODEL NUMBER: A07LB27 ENGINE MODEL: ES30PFE JETTING CHART CLUTCH CHART Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES300PFE010 Engine Displacement 299cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm Compression Ratio 9.2:1 Full Stroke Compression Pressure 120-140 psi Engine Idle Speed 1400 RPM Cooling System/Capacity Air/Oil Cooled Overheat Warning None Lubrication Wet Sump Oil Requirements Polaris 0W-50 / 1.7 qts (1.6L) Exhaust System Single Pipe - USFS Approved Carburetion Carburetor model Mikuni BST 34mm Main Jet 140 Pilot Jet 45 Jet Needle 4HC57-3 Needle Jet 05-m Pilot/Air Screw 2.5 Turns Out (Initial setting) Float Height 13mm from carburetor body Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.5 gal. (17 L) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 250 watt / 18.6 Amp @ 6000 Voltage Regulator 3-phase Lights : High Beam -- Low Beam 37.5 watts Brake 12V / 26.9 watts Tail 12V / 8.26 watts Ignition System DC CDI Ignition Timing BTDC 30°+/-2 @ 5000 RPM Spark plug / Gap NGK CR8EB .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 Drivetrain Transmission Type H-N-R Transmission Capacity Level with fill plug Gear Ratio : Foward Reverse 15.18:1 14.05:1 Clutch Type CVT w/EBS Belt 3211108 Steering / Suspension Front Suspension / Shock Mac Pherson Strut Front Travel 7 in. / 17.8 cm Rear Suspension Style / Shock Independent Coil-over Adjustable Rear Travel 8 in. / 20.3 cm Ground Clearance 8 in. / 20.3 cm Shock Preload Adjustment Front / Rear Front - Cam Rear - Cam Turning Radius 62.5 in. (159 cm) unloaded Toe Out 0-1/16 in. (0-.159 mm) Wheels / Brakes Tire/Rim Size - Front 22 x 7-12 Tire/Rim Size - Rear 22 x 10-12 Air Press. F/R Tires 3-5 psi Brake - Front Single Control Hydraulic Disc Brake - Rear Single Control Hydraulic Disc Brake Fluid Polaris DOT 3 or 4 Brake Fluid Altitude AMBIENT TEMPERATURE Below 40 o F Below 5 o C Above +40 o F Above +5 o C Meters (Feet) 0-1800 (0-6000) 145 140 1800-3700 (6000-12000) 140 135 Altitude Shift Weight Number Installed Feet (Meters) 0-5000 (0-1534) 13 g 5412988 8 5000-10,000 (1534 - 3048) 10 g 5412986 8 10,000 + (3048 +) 10 g 5412986 6 Note: Remove opposite rollers to retain proper clutch balance

1.5 GENERAL INFORMATION 1 MODEL: 2007 HAWKEYE 4x4 MODEL NUMBER: A07LH27 ENGINE MODEL: ES30PFE JETTING CHART CLUTCH CHART Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES300PFE010 Engine Displacement 299cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm Compression Ratio 9.2:1 Full Stroke Compression Pressure 120-140 psi Engine Idle Speed 1400 RPM Cooling System/Capacity Air/Oil Cooled Overheat Warning None Lubrication Wet Sump Oil Requirements Polaris 0W-50 / 1.7 qts (1.6L) Exhaust System Single Pipe - USFS Approved Carburetion Carburetor model Mikuni BST 34mm Main Jet 140 Pilot Jet 45 Jet Needle 4HC57-3 Needle Jet 05-m Pilot/Air Screw 2.5 Turns Out (Initial setting) Float Height 13mm from carburetor body Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.5 gal. (17 L) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 250 watt / 18.6 Amp @ 6000 Voltage Regulator 3-phase Lights : High Beam -- Low Beam 37.5 watts Brake 12V / 26.9 watts Tail 12V / 8.26 watts Ignition System DC CDI Ignition Timing BTDC 30°+/-2deg. @ 5000 RPM Spark plug / Gap NGK CR8EB .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 Drivetrain Transmission Type H-N-R Transmission Capacity Level with fill plug Front Gearcase Capacity Level with fill plug Gear Ratio : Front Output Rear Output Fwd 5.17:1 / Rev 4.79:1 Fwd 15.18:1 / Rev 14.05:1 Clutch Type CVT w/EBS Belt 3211108 Steering / Suspension Front Suspension / Shock Mac Pherson Strut Front Travel 7 in. / 17.8 cm Rear Suspension Style / Shock Independent Coil-over Adjustable Rear Travel 8 in. / 20.3 cm Ground Clearance 8 in. / 20.3 cm Shock Preload Adjustment Front / Rear Front - Cam Rear - Cam Turning Radius 62.5 in. (159 cm) unloaded Toe Out 0-1/16 in. (0-.159 mm) Wheels / Brakes Tire/Rim Size - Front 22 x 7-12 Tire/Rim Size - Rear 22 x 10-12 Air Press. F/R Tires 3-5 psi Brake - Front Single Control Hydraulic Disc Brake - Rear Single Control Hydraulic Disc Brake Fluid Polaris DOT 3 or 4 Brake Fluid Altitude AMBIENT TEMPERATURE Below 40 o F Below 5 o C Above +40 o F Above +5 o C Meters (Feet) 0-1800 (0-6000) 145 140 1800-3700 (6000-12000) 140 135 Altitude Shift Weight Number Installed Feet (Meters) 0-5000 (0-1534) 13 g 5412988 8 5000-10,000 (1534 - 3048) 10 g 5412986 8 10,000 + (3048 +) 10 g 5412986 6 Note: Remove opposite rollers to retain proper clutch balance

1.6 GENERAL INFORMATION GENERAL INFORMATION Publication Numbers NOTE: When ordering service parts, be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from www.purepolaris.com. 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 for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary. Year Model Model No. Owner’s Manual PN Parts Manual PN 2007 Hawkeye 2x4 A07LB27AA, AC 9920787 9920789 2007 Hawkeye 4x4 A07LH27AA, AB, AC, AD 9920787 9920789 2007 Hawkeye 2x4 Intl’ A07LB27FB 9920788 9920790 2007 Hawkeye 4x4 Intl’ A07LH27FA 9920788 9920790 Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

1.7 GENERAL INFORMATION 1 Standard Torque Specifications The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS, refer to the exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections. Bolt Size Threads/In Grade 2 Grade 5 Grade 8 Torque in. lbs. (Nm) #10 - 24 . . . . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . 43 (5.0) . . . . . . . . . 60 (6.9) #10 - 32 . . . . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . 49 (5.6) . . . . . . . . . 68 (7.8) Torque ft. lbs. (Nm)* 1/4 - 20 . . . . . . . . . . . . . . . . . 5 (7) . . . . . . . . . . . . 8 (11) . . . . . . . . . . . 12 (16) 1/4 - 28 . . . . . . . . . . . . . . . . . 6 (8) . . . . . . . . . . . . 10 (14) . . . . . . . . . . 14 (19) 5/16 - 18 . . . . . . . . . . . . . . . . . 11(15) . . . . . . . . . . 17 (23) . . . . . . . . . . 25 (35) 5/16 - 24 . . . . . . . . . . . . . . . . . 12(16) . . . . . . . . . . 19 (26) . . . . . . . . . . 29 (40) 3/8 - 16 . . . . . . . . . . . . . . . . . 20(27) . . . . . . . . . . 30 (40) . . . . . . . . . . 45 (62) 3/8 - 24 . . . . . . . . . . . . . . . . . 23(32) . . . . . . . . . . 35 (48) . . . . . . . . . . 50 (69) 7/16 - 14 . . . . . . . . . . . . . . . . . 30(40) . . . . . . . . . . 50 (69) . . . . . . . . . . 70 (97) 7/16 - 20 . . . . . . . . . . . . . . . . . 35(48) . . . . . . . . . . 55 (76) . . . . . . . . . . 80 (110) 1/2 - 13 . . . . . . . . . . . . . . . . . 50(69) . . . . . . . . . . 75 (104). . . . . . . . . 110 (152) 1/2 - 20 . . . . . . . . . . . . . . . . . 55(76) . . . . . . . . . . 90 (124). . . . . . . . . 120 (166) Metric / Torque 6 x 1.0. . . . . . . . . . 72-78 In.lbs. . . . . . . . . . 8 x 1.25 14-18 ft.lbs . . . . 10 x 1.25 26-30 ft.lbs.

1.8 GENERAL INFORMATION Sae Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents 1/64 . . . . . . . . . . . . . . . . . .0156 1/32 . . . . . . . . . . . . . .0312. . . 1 mm= .0394" 3/64 . . . . . . . . . . . . . . . . . .0469 1/16 . . . . . . . . . . . . . .0625 5/64 . . . . . . . . . . . . . . . . . .0781. . . 2 mm = .0787" 3/32 . . . . . . . . . . . . . .0938 7/64 . . . . . . . . . . . . . . . . . .1094. . . 3 mm =.1181" 1/8 . . . . . . . .1250 9/64 . . . . . . . . . . . . . . . . . .1406 5/32 . . . . . . . . . . . . . .1563. . . 4 mm = .1575" 11/64 . . . . . . . . . . . . . . . . . .1719 3/16 . . . . . . . . . . . . . .1875. . . 5mm= .1969" 13/64 . . . . . . . . . . . . . . . . . .2031 7/32 . . . . . . . . . . . . . .2188 15/64 . . . . . . . . . . . . . . . . . .2344. . . 6 mm = .2362" 1/4 . . . . . . . .25 17/64 . . . . . . . . . . . . . . . . . .2656. . . 7 mm = .2756" 9/32 . . . . . . . . . . . . . .2813 19/64 . . . . . . . . . . . . . . . . . .2969 5/16 . . . . . . . . . . . . . .3125. . . 8mm= .3150" 21/64 . . . . . . . . . . . . . . . . . .3281 11/32 . . . . . . . . . . . . .3438. . . 9 mm = .3543" 23/64 . . . . . . . . . . . . . . . . . .3594 3/8 . . . . . . . .375 25/64 . . . . . . . . . . . . . . . . . .3906. . . 10 mm = .3937" 13/32 . . . . . . . . . . . . .4063 27/64 . . . . . . . . . . . . . . . . . .4219. . . 11 mm =.4331" 7/16 . . . . . . . . . . . . . .4375 29/64 . . . . . . . . . . . . . . . . . .4531 15/32 . . . . . . . . . . . . .4688. . . 12 mm = .4724" 31/64 . . . . . . . . . . . . . . . . . .4844 1/2 . . . . . . . .5 . . . . . . . . . . . . 13mm = .5118" 33/64 . . . . . . . . . . . . . . . . . .5156 17/32 . . . . . . . . . . . . .5313 35/64 . . . . . . . . . . . . . . . . . .5469. . . 14 mm = .5512" 9/16 . . . . . . . . . . . . . .5625 37/64 . . . . . . . . . . . . . . . . . .5781. . . 15 mm = .5906" 19/32 . . . . . . . . . . . . .5938 39/64 . . . . . . . . . . . . . . . . . .6094 5/8 . . . . . . . .625 . . . . . . . . . . 16mm=. 6299" 41/64 . . . . . . . . . . . . . . . . . .6406 21/32 . . . . . . . . . . . . .6563. . . 17 mm =.6693" 43/64 . . . . . . . . . . . . . . . . . .6719 11/16 . . . . . . . . . . . . .6875 45/64 . . . . . . . . . . . . . . . . . .7031. . . 18 mm = .7087" 23/32 . . . . . . . . . . . . .7188 47/64 . . . . . . . . . . . . . . . . . .7344. . . 19 mm = .7480" 3/4 . . . . . . . .75 49/64 . . . . . . . . . . . . . . . . . .7656 25/32 . . . . . . . . . . . . .7813. . . 20 mm = .7874" 51/64 . . . . . . . . . . . . . . . . . .7969 13/16 . . . . . . . . . . . . .8125. . . 21 mm =.8268" 53/64 . . . . . . . . . . . . . . . . . .8281 27/32 . . . . . . . . . . . . .8438 55/64 . . . . . . . . . . . . . . . . . .8594. . . 22 mm = .8661" 7/8 . . . . . . . .875 57/64 . . . . . . . . . . . . . . . . . .8906. . . 23 mm = .9055" 29/32 . . . . . . . . . . . . .9063 59/64 . . . . . . . . . . . . . . . . . .9219 15/16 . . . . . . . . . . . . .9375. . . 24 mm = .9449" 61/64 . . . . . . . . . . . . . . . . . .9531 31/32 . . . . . . . . . . . . .9688. . . 25 mm = .9843" 63/64 . . . . . . . . . . . . . . . . . .9844 1 . . . . . . . . . 1.0 Thread Size/ Drill Size Thread Size / Drill Size #0-80 3/64 1/2-13 27/64 #1-64 53 1/2-20 29/64 #1-72 53 9/16-12 31/64 #2-56 51 9/16-18 33/64 #2-64 50 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 45 3/4-10 21/32 #4-40 43 3/4-16 11/16 #4-48 42 7/8-9 49/64 #5-40 38 7/8-14 13/16 #5-44 37 1-8 7/8 #6-32 36 1-12 59/64 #6-40 33 1 1/8-7 63/64 #8-32 29 1 1/8-12 1 3/64 #8-36 29 1 1/4-7 1 7/64 #10-24 24 1 1/4-12 1 11/64 #10-32 21 1 1/2-6 1 11/32 #12-24 17 1 1/2-12 1 27/64 #12-28 4.6mm 1 3/4-5 1 9/16 1/4-20 7 1 3/4-12 1 43/64 1/4-28 3 2-4 1/2 1 25/32 5/16-18 F 2-12 1 59/64 5/16-24 I 2 1/4-4 1/2 2 1/32 3/8-16 O 2 1/2-4 2 1/4 3/8-24 Q 2 3/4-4 2 1/2 7/16-14 U 3-4 2 3/4 7/16-20 25/64 Tap Size Drill Size Decimal Equivalent Nearest Fraction 3x.50 #39 0.0995 3/32 3x.60 3/32 0.0937 3/32 4x.70 #30 0.1285 1/8 4x.75 1/8 0.125 1/8 5x.80 #19 0.166 11/64 5x.90 #20 0.161 5/32 6x1.00 #9 0.196 13/64 7x1.00 16/64 0.234 15/64 8x1.00 J 0.277 9/32 8x1.25 17/64 0.265 17/64 9x1.00 5/16 0.3125 5/16 9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 R 0.339 11/32 11x1.50 3/8 0.375 3/8 12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32

1.9 GENERAL INFORMATION 1 Conversion Table °C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: 5 (°F + 40) ÷ 9 - 40 = °C Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz.) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounces (oz.) lb. x .454 = kg kg x 2.2046 = lb. Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in) Imperial pints (Imp pt.) x 0.568 = Liters (l) Liters (l) x 1.76 = Imperial pints (Imp pt.) Imperial quarts (Imp qt.) x 1.137 = Liters (l) Liters (l) x 0.88 = Imperial quarts (Imp qt.) Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.) US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.) US quarts (US qt.) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt.) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa) π(3.14)xR 2 x H (height) = Cylinder Volume

1.10 GENERAL INFORMATION Glossary Of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm 2 : Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in 2 : Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT : Wide open throttle.

2007 Polaris Hawkeye ATV Service & Repair Manual

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