2006 Polaris Hawkeye 300 ATV Repair Manual

1.1 GENERAL INFORMATION 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: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 projex@inbox.lv

1.2 GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Numbe r ES30PFE ............................................................ Single, Air Cooled, SOHC 4 Stroke, Electric Start 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. The machine serial number (1- lower frame rail) and engine number (2- right side engine) are important for vehicle identification. } Machine Model Number Identification } } Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option A 0 6 LB 2 7 A A } 4 X A P B 2 0 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 projex@inbox.lv

1.3 GENERAL INFORMATION SPECIFICATIONS MODEL: 2006 HAWKEYE 2x4 MODEL NUMBER: . . . . . . . . . A06LB27AA ENGINE MODEL: . . . . . . . . . . ES30PFE MODEL: . . . . . . . . . . . . 2006 HAWKEYE 4x4 MODEL NUMBER: . . . . . . . . . A06LD27AA 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 projex@inbox.lv

GENERAL INFORMATION 1.4 MODEL: 2006 HAWKEYE 2x4 MODEL NUMBER: A06LB27AA 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 Compression Relase 60-90 psi Engine Idle Speed 1300 RPM Cooling System/Capacity Air/Oil Cooled Overheat Warning None Lubrication Wet Sump Oil Requirements Polaris 0W-50 / 2 qts (1.9L) Exhaust System Single Pipe - USFS Approved Carburetion Carburetor model Mikuni BST 34mm Main Jet 147.5 Pilot Jet 42.5 Jet Needle 4HB42-5 Needle Jet 0-4m 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 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 Drivetrain Transmission Type H-N-R Transmission Capacity 15.2 oz. (450 ml) 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) 152.5 147.5 1800-3700 (6000-12000) 147.5 142.5 Altitude Shift Weight Meters (Feet) 0-1800 (0-6000) 14 g (Yellow) 5412989 1800-3700 (6000 - 12000) 12 g (Red) 5412987 projex@inbox.lv

1.5 GENERAL INFORMATION MODEL: 2006 HAWKEYE 4x4 MODEL NUMBER: A06LD27AA 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 Compression Relase 60-90 psi Engine Idle Speed 1300 RPM Cooling System/Capacity Air/Oil Cooled Overheat Warning None Lubrication Wet Sump Oil Requirements Polaris 0W-50 / 2 qts (1.9L) Exhaust System Single Pipe - USFS Approved Carburetion Carburetor model Mikuni BST 34mm Main Jet 147.5 Pilot Jet 42.5 Jet Needle 4HB42-5 Needle Jet 0-4m 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 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 Drivetrain Transmission Type H-N-R Transmission Capacity 15.2 oz. (450 ml) 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) 152.5 147.5 1800-3700 (6000-12000) 147.5 142.5 Altitude Shift Weight Meters (Feet) 0-1800 (0-6000) 14 g (Yellow) 5412989 1800-3700 (6000 - 12000) 12 g (Red) 5412987 projex@inbox.lv

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 the right 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 Parts Micro Fiche PN 2006 Hawkeye 2x4 A06LB27AA 9920202 9920207 9920208 2006 Hawkeye 4x4 A06LD27AB,AC 9920202 9920207 9920208 Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 projex@inbox.lv

1.7 GENERAL INFORMATION SPECIAL 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. Standard Tools and Engine Tools 2871293 - B - Crankshaft Slotted Nut Socket PA - 47344 - Balance Shaft Slotted Nut Socket 2870975 - Mity Vac TM 2870773 - C - Clip Install Tool 2870390 - Piston Support Block PA-47478 - Drive Clutch Holder Standard Tools and Engine Tools 2870569 - Crankshaft True Kit PV - 35667 - A - Cylinder Leakdown Tester PU - 45432 - Caliper or A Basic Caliper Suspension Tools 2870871 - ATV Ball Joint Tool Kit 2870623 - Shock Spring Compressor projex@inbox.lv

1.8 GENERAL INFORMATION Standard Tools and Engine Tools 2870303- Hone Kit 2870305 - Stone Replacement Kit 2870588 - Hone Oil (12 OZ.) 2200634 - Valve Seat Reconditioning Kit 2870459 - Dial Indicator Electrical Tools PV-43568 - Fluke TM 77 Multimeter PV-39617 - Current Clamp 2870836 - Battery Hydrometer 8712500 - PV-39951-A Tachometer Tachometer projex@inbox.lv

1.9 GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to 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. projex@inbox.lv

1.10 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 projex@inbox.lv

2006 Polaris Hawkeye 300 ATV Repair Manual

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