Category Archives: Polaris

POLARIS SERVICE REPAIR MANUAL ATV HAWKEYE 300 2×4 4×4 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

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COMPLETE POLARIS SERVICE REPAIR MANUAL ATV HAWKEYE 300 2×4 4×4 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Hundreds pages of diagrams and instructions, written for the do-it-yourself as well as the experienced mechanic. Everything You Will Ever Need To Repair, Maintain, Rebuild, Refurbish or Restore Your Vehicle. With this Step by Step Repair Manual You can easily disassembly and assembly (overhaul) even engine. This is same manual which your local diller use to service and repair your Polaris. _____________________________________________________________ * FEATURES and IMPROVEMENTS of this PDF manual: -Bookmarks -Sub bookmarks -Index -Searchable Text -Improved Quality (NOT A SCAN!) -Fully Printable -Ability to make a Backup CD * COMPATIBLE with OS: -compatible with ALL Windows, ALL Mac, ALL Linux OS’s * Easy To USE: -Fully searchable Index…It means you don’t need to dig through hundreds of pages -NOT a zip file… easy to use PDF ______________________________________________________________ *** MODELS POLARIS HAWKEYE 300 2×4 4×4 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 *** CONTENT * General Information * Maintenance * Engine * Fuel/Carburation * Body / Steering / Suspension * Clutching * Final Drive * Transmission * Brakes * Electrical * Wiring Diagrams ______________________________________________________________ RELATED ATV SERVICE MANUAL SEARCHES: FRAME/BODY PANELS/EXHAUST SYSTEM TROUBLESHOOTING Excessive exhaust noise * Deformed exhaust system * Exhaust gas leaks Poor performance * Clogged muffler * Broken exhaust system * Exhaust gas leaks LUBRICATION SYSTEM TROUBLESHOOTING Oil level too low – high oil consumption * Oil consumption * External oil leak * Worn piston rings or incorrect piston ring installation * Worn cylinder * Worn valve guide or stem seals * Oil pump worn or damaged Oil contamination * Oil or filter not changed often enough * Worn piston rings or incorrect piston ring installation * Worn valve guide or stem seals FUEL SYSTEM TROUBLESHOOTING Engine cranks but wont start * No fuel in tank * No fuel to carburetor * Clogged fuel strainer * Clogged fuel line * Clogged fuel tank breather tube * Misadjusted fuel level * Too much fuel getting to the engine * Clogged air cleaner * Flooded carburetor * Intake air leak * Contaminated/deteriorated fuel * Clogged jets * Clogged starting enrichment valve circuit * Improper starting enrichment valve operation * Improper throttle operation * No spark at plug (faulty ignition system) Lean mixture * Clogged fuel jets * Faulty float valve * Float level too low * Restricted fuel line * Clogged carburetor air vent tube * Restricted fuel tank breather tube * Intake air leak * Faulty vacuum piston * Faulty throttle valve Rich mixture * Starting enrichment valve open (ON) * Clogged air jets * Faulty float valve * Float level too high * Dirty air cleaner * Worn jet needle or needle jet * Faulty vacuum piston Engine stalls, hard to start, rough idling * Restricted fuel line * Fuel mixture too lean/rich * Contaminated/deteriorated fuel * Clogged jets * Intake air leak * Misadjusted idle speed * Misadjusted pilot screw * Misadjusted float level * Restricted fuel tank breather tube * Clogged air cleaner * Clogged slow circuit * Clogged starting enrichment valve circuit * Faulty ignition system Afterburn when engine braking is used * Leanmixture in slow circuit * Faulty air cut-off valve * Faulty ignition system Backfiring or misfiring during acceleration * Leanmixture * Faulty ignition system Poor performance (driveability) and poor fuel economy * Clogged fuel system * Faulty ignition system CYLINDER HEAD/VALVE TROUBLESHOOTING Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. If the performance is poor at low speeds, check for a white smoke in the crankcase breather tube. If the tube is smoky, check for seized piston ring Compression too low, hard starting or poor performance at low speed Valves Incorrect valve adjustment Burned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Valve stuck open Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Compression too high Excessive carbon build-up on piston head or combustion chamber Worn or damaged decompressor system Excessive smoke Worn valve stem or valve guide Damaged stemseal Cylinder/piston problem Excessive noise Incorrect valve clearance Sticking valve or broken valve spring Excessive worn valve seat Worn or damaged camshaft Worn rocker arm and/or shaft Worn rocker arm follower or valve stem end Worn or damaged push rod and/or cam follower Worn cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth Cylinder/piston problem Rough idle Low cylinder compression CYLINDER/PISTON TROUBLESHOOTING Compression too low, hard starting or poor performance at low speed * Leaking cylinder head gasket * Worn, stuck or broken piston ring * Worn or damaged cylinder and piston * Bent connecting rod Compression too high, overheating or knocking * Excessive carbon built-up on piston head or combustion chamber Excessive smoke * Worn cylinder, piston or piston rings * Improper installation of piston rings * Scored or scratched piston or cylinder wall Abnormal noise * Worn piston pin or piston pin hole * Worn connecting rod small end * Worn cylinder, piston or piston rings CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Clutch slips when accelerating * Incorrect clutch adjustment * Worn clutch discs * Weak clutch springs * Faulty clutch lifter * Improper oil viscosity or oil additive used Clutch will not disengage * Faulty clutch lifter * Warped clutch plates The vehicle creeps * Faulty centrifugal clutch Clutch operating feels rough * Worn clutch outer and center grooves * Warped clutch plates * Loose clutch lock nut * Faulty clutch lifter * Improper oil viscosity or oil level Hard to shift * Incorrect clutch adjustment * Worn or damaged gearshift cam and stopper arm * Faulty clutch lifter * Improper engine oil viscosity * Bent fork shaft and gearshift spindle or damaged shift forks and shift drum Transmission jumps out of gear * Broken shift drum stopper arm * Weak or broken shift linkage return springs * Worn or damaged gearshift cam * Bent fork shaft or worn shift forks and shift drum * Worn gear dogs or slots ALTERNATOR/STARTER CLUTCH TROUBLESHOOTING Starter motor turns, but engine does not turn * Faulty starter clutch * Damaged starter reduction gear CRANKCASE/TRANSMISSION/CRANKSHAFT TROUBLESHOOTING Excessive engine noise * Worn, seized or chipped transmission gears * Worn transmission bearings * Worn or damaged connecting rod bearing * Worn crankshaftmain journal bearing * Worn connecting rod small end * Worn balancer bearing * Improper balancer installation Transmission jumps out of gear * Worn gear dogs or dog holes * Worn shift drum guide groove * Worn shift fork guide pin * Worn gear shifter groove * Worn shift fork * Bent shift fork shaft Hard to shift * Damaged shift fork * Bent shift fork shaft * Damaged shift fork guide pin * Damaged shift drum guide groove Abnormal vibration * Improper balancer timing FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING Hard steering * Steering shaft holder too tight * Damaged steering shaft bearing/bushing * Insufficient tire pressure Steers one side or does not track straight * Incorrect wheel alignment * Unequal tire pressure * Bent tie-rod, suspension arm or frame * Worn or damaged knuckle bearing or brake drum bearing * Weak shock absorber Front wheel wobbling * Bent rim * Worn or damaged knuckle bearing or brake drum bearing * Faulty tire * Axle nut not tightened properly Soft suspension * Weak shock absorber spring * Faulty shock absorber damper Hard suspension * Bent shock absorber damper rod * Improperly installed suspension arms * Faulty suspension arm bushings Front suspension noise * Loose front suspension fasteners * Damaged suspension components REAR WHEEL/SUSPENSION TROUBLESHOOTING Rear wheel wobbling * Bent rim * Worn or damaged rear axle bearings * Faulty rear tire * Axle fastener not tightened properly * Faulty swingarm pivot bearings Rear wheel turns hard * Faulty rear axle bearings * Bent rear axle * Rear brake drag Soft suspension * Weak shock absorber spring * Oil leakage fromdamper unit Hard suspension * Damaged rear suspension pivot bearing or bushing * Damaged swingarm pivot bearing * Improperly tightened swingarm pivot Rear suspension noise * Faulty rear shock absorber * Loose rear suspension fasteners * Worn rear suspension pivot bearing or bushing BRAKE SYSTEM TROUBLE SHOOTING Front wheel wobbling and noise * Worn brake shoes Poor brake performance * Brake not adjusted properly * Worn brake shoes and drum * Water in brake drum * Contaminated brake shoes and drum * Air in hydraulic system * Leaking hydraulic system * Clogged/restricted fluid passage * Incorrectly installed rear brake arm * Worn rear brake cam FRONT DRIVING MECHANISM TROUBLE SHOOTING Consistent noise during cruising * Oil level too low * Foreignmatter contaminating gear oil * Worn or damaged bearing * Worn or damaged ring gear and pinion gear * Deformed ring gear or differential case * Improper tooth contact between ring gear and pinion gear Gear noises while running * Oil level too low * Foreignmatter contaminating gear oil * Chipped or damaged gears * Improper tooth contact between ring gear and pinion gear Gear noises while coasting * Damage or chipped gears Abnormal noises when turning * Worn or damaged ring gear bearing * Worn or damaged face cam and cam follower * Worn or damaged differential housing groove * Worn cone spring or shim Abnormal noises at start or during acceleration * Excessive backlash between ring gear and pinion gear * Worn differential splines * Loose fasteners * Worn cone spring or shim Oil leak * Oil level too high * Clogged breather * Damaged seals * Loose case cover bolt Over heating * Oil level too low * Insufficient backlash between ring gear and pinion gear REAR DRIVING MECHANISM TROUBLE SHOOTING Excessive noise * Worn or scored ring gear shaft and axle * Worn or scored pinion and splines * Worn pinion and ring gears * Excessive backlash between pinion and ring gears * Oil level too low Wobble or vibration in vehicle * Axle not tightened properly * Bent axle Oil leak * Oil level too high * Clogged breather * Damaged seals * Loose case cover bolt keywords: POLARIS SERVICE REPAIR MANUAL ATV HAWKEYE 300 2×4 4×4 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 service, shop, workshop, pdf, ebook, paypal, echeck, free support, manuals, buy, downloads, atv, utv,

POLARIS ATV SERVICE MANUAL RANGER and RANGER TM 2×4 4×4 6×6 DOWNLOAD

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This is the COMPLETE official full factory service repair manual from POLARIS for the RANGER AND RANGER TM. Production model years 2004 2005 2006 2007 2008 2009. Over 400 pages allow you to print it out in its entirety or just the pages you need!! These manuals are your number one source for repair and service information. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Using this repair manual is an inexpensive way to keep your equipment working properly. Each manual provides step-by-step instructions based on the complete disassembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. * Detailed substeps expand on repair procedure information * Notes, cautions and warnings throughout each chapter pinpoint critical information. * Numbered instructions guide you through every repair procedure step by step. * Bold figure number help you quickly match illustrations with instructions. * Detailed illustrations, drawings and photos guide you through every procedure. * Enlarged inset helps you identify and examine parts in detail. * Numbered table of contents easy to use so that you can find the information you need fast. * This manual also makes it easy to diagnose and repair problems with your machines electrical system. Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also. It saves to your hard-drive and can be burned to CD-ROM. All pages are printable. No need to pay for shipping and wait for the overpriced paper textbook or CD-ROM to arrive via snail mail. DOWNLOAD IT NOW!! RELATED ATV SERVICE MANUAL SEARCHES: FRAME/BODY PANELS/EXHAUST SYSTEM TROUBLESHOOTING Excessive exhaust noise * Deformed exhaust system * Exhaust gas leaks Poor performance * Clogged muffler * Broken exhaust system * Exhaust gas leaks LUBRICATION SYSTEM TROUBLESHOOTING Oil level too low – high oil consumption * Oil consumption * External oil leak * Worn piston rings or incorrect piston ring installation * Worn cylinder * Worn valve guide or stem seals * Oil pump worn or damaged Oil contamination * Oil or filter not changed often enough * Worn piston rings or incorrect piston ring installation * Worn valve guide or stem seals FUEL SYSTEM TROUBLESHOOTING Engine cranks but wont start * No fuel in tank * No fuel to carburetor * Clogged fuel strainer * Clogged fuel line * Clogged fuel tank breather tube * Misadjusted fuel level * Too much fuel getting to the engine * Clogged air cleaner * Flooded carburetor * Intake air leak * Contaminated/deteriorated fuel * Clogged jets * Clogged starting enrichment valve circuit * Improper starting enrichment valve operation * Improper throttle operation * No spark at plug (faulty ignition system) Lean mixture * Clogged fuel jets * Faulty float valve * Float level too low * Restricted fuel line * Clogged carburetor air vent tube * Restricted fuel tank breather tube * Intake air leak * Faulty vacuum piston * Faulty throttle valve Rich mixture * Starting enrichment valve open (ON) * Clogged air jets * Faulty float valve * Float level too high * Dirty air cleaner * Worn jet needle or needle jet * Faulty vacuum piston Engine stalls, hard to start, rough idling * Restricted fuel line * Fuel mixture too lean/rich * Contaminated/deteriorated fuel * Clogged jets * Intake air leak * Misadjusted idle speed * Misadjusted pilot screw * Misadjusted float level * Restricted fuel tank breather tube * Clogged air cleaner * Clogged slow circuit * Clogged starting enrichment valve circuit * Faulty ignition system Afterburn when engine braking is used * Leanmixture in slow circuit * Faulty air cut-off valve * Faulty ignition system Backfiring or misfiring during acceleration * Leanmixture * Faulty ignition system Poor performance (driveability) and poor fuel economy * Clogged fuel system * Faulty ignition system CYLINDER HEAD/VALVE TROUBLESHOOTING Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. If the performance is poor at low speeds, check for a white smoke in the crankcase breather tube. If the tube is smoky, check for seized piston ring Compression too low, hard starting or poor performance at low speed Valves Incorrect valve adjustment Burned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Valve stuck open Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Compression too high Excessive carbon build-up on piston head or combustion chamber Worn or damaged decompressor system Excessive smoke Worn valve stem or valve guide Damaged stemseal Cylinder/piston problem Excessive noise Incorrect valve clearance Sticking valve or broken valve spring Excessive worn valve seat Worn or damaged camshaft Worn rocker arm and/or shaft Worn rocker arm follower or valve stem end Worn or damaged push rod and/or cam follower Worn cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth Cylinder/piston problem Rough idle Low cylinder compression CYLINDER/PISTON TROUBLESHOOTING Compression too low, hard starting or poor performance at low speed * Leaking cylinder head gasket * Worn, stuck or broken piston ring * Worn or damaged cylinder and piston * Bent connecting rod Compression too high, overheating or knocking * Excessive carbon built-up on piston head or combustion chamber Excessive smoke * Worn cylinder, piston or piston rings * Improper installation of piston rings * Scored or scratched piston or cylinder wall Abnormal noise * Worn piston pin or piston pin hole * Worn connecting rod small end * Worn cylinder, piston or piston rings CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Clutch slips when accelerating * Incorrect clutch adjustment * Worn clutch discs * Weak clutch springs * Faulty clutch lifter * Improper oil viscosity or oil additive used Clutch will not disengage * Faulty clutch lifter * Warped clutch plates The vehicle creeps * Faulty centrifugal clutch Clutch operating feels rough * Worn clutch outer and center grooves * Warped clutch plates * Loose clutch lock nut * Faulty clutch lifter * Improper oil viscosity or oil level Hard to shift * Incorrect clutch adjustment * Worn or damaged gearshift cam and stopper arm * Faulty clutch lifter * Improper engine oil viscosity * Bent fork shaft and gearshift spindle or damaged shift forks and shift drum Transmission jumps out of gear * Broken shift drum stopper arm * Weak or broken shift linkage return springs * Worn or damaged gearshift cam * Bent fork shaft or worn shift forks and shift drum * Worn gear dogs or slots ALTERNATOR/STARTER CLUTCH TROUBLESHOOTING Starter motor turns, but engine does not turn * Faulty starter clutch * Damaged starter reduction gear CRANKCASE/TRANSMISSION/CRANKSHAFT TROUBLESHOOTING Excessive engine noise * Worn, seized or chipped transmission gears * Worn transmission bearings * Worn or damaged connecting rod bearing * Worn crankshaftmain journal bearing * Worn connecting rod small end * Worn balancer bearing * Improper balancer installation Transmission jumps out of gear * Worn gear dogs or dog holes * Worn shift drum guide groove * Worn shift fork guide pin * Worn gear shifter groove * Worn shift fork * Bent shift fork shaft Hard to shift * Damaged shift fork * Bent shift fork shaft * Damaged shift fork guide pin * Damaged shift drum guide groove Abnormal vibration * Improper balancer timing FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING Hard steering * Steering shaft holder too tight * Damaged steering shaft bearing/bushing * Insufficient tire pressure Steers one side or does not track straight * Incorrect wheel alignment * Unequal tire pressure * Bent tie-rod, suspension arm or frame * Worn or damaged knuckle bearing or brake drum bearing * Weak shock absorber Front wheel wobbling * Bent rim * Worn or damaged knuckle bearing or brake drum bearing * Faulty tire * Axle nut not tightened properly Soft suspension * Weak shock absorber spring * Faulty shock absorber damper Hard suspension * Bent shock absorber damper rod * Improperly installed suspension arms * Faulty suspension arm bushings Front suspension noise * Loose front suspension fasteners * Damaged suspension components REAR WHEEL/SUSPENSION TROUBLESHOOTING Rear wheel wobbling * Bent rim * Worn or damaged rear axle bearings * Faulty rear tire * Axle fastener not tightened properly * Faulty swingarm pivot bearings Rear wheel turns hard * Faulty rear axle bearings * Bent rear axle * Rear brake drag Soft suspension * Weak shock absorber spring * Oil leakage fromdamper unit Hard suspension * Damaged rear suspension pivot bearing or bushing * Damaged swingarm pivot bearing * Improperly tightened swingarm pivot Rear suspension noise * Faulty rear shock absorber * Loose rear suspension fasteners * Worn rear suspension pivot bearing or bushing BRAKE SYSTEM TROUBLE SHOOTING Front wheel wobbling and noise * Worn brake shoes Poor brake performance * Brake not adjusted properly * Worn brake shoes and drum * Water in brake drum * Contaminated brake shoes and drum * Air in hydraulic system * Leaking hydraulic system * Clogged/restricted fluid passage * Incorrectly installed rear brake arm * Worn rear brake cam FRONT DRIVING MECHANISM TROUBLE SHOOTING Consistent noise during cruising * Oil level too low * Foreignmatter contaminating gear oil * Worn or damaged bearing * Worn or damaged ring gear and pinion gear * Deformed ring gear or differential case * Improper tooth contact between ring gear and pinion gear Gear noises while running * Oil level too low * Foreignmatter contaminating gear oil * Chipped or damaged gears * Improper tooth contact between ring gear and pinion gear Gear noises while coasting * Damage or chipped gears Abnormal noises when turning * Worn or damaged ring gear bearing * Worn or damaged face cam and cam follower * Worn or damaged differential housing groove * Worn cone spring or shim Abnormal noises at start or during acceleration * Excessive backlash between ring gear and pinion gear * Worn differential splines * Loose fasteners * Worn cone spring or shim Oil leak * Oil level too high * Clogged breather * Damaged seals * Loose case cover bolt Over heating * Oil level too low * Insufficient backlash between ring gear and pinion gear REAR DRIVING MECHANISM TROUBLE SHOOTING Excessive noise * Worn or scored ring gear shaft and axle * Worn or scored pinion and splines * Worn pinion and ring gears * Excessive backlash between pinion and ring gears * Oil level too low Wobble or vibration in vehicle * Axle not tightened properly * Bent axle Oil leak * Oil level too high * Clogged breather * Damaged seals * Loose case cover bolt

Polaris 1992-97 SLT SL SLTX 650 700 750 800.. Service Manual

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POLARIS full Repair Manual 1992 – 1997 This CD contains a full service repair manuals, Covering all 650 to 1050 Series personal watercraft. from 1992 upto 1997. SL650 Series SL750 Series SLT750 Series SLX780 Series SL700 Series SLT700 Series SL780 Series SLT780 Series SL900 Series SLTX SeriesSL700 Deluxe SL1050 Series Hurricanne Series Step-by-step illustrated keyed procedures guide you through every conceivable job , including all adjustments . All jobs covered from general maintenence to full stripdown repir and rebuild. Separate chapters cover: General information; tools and equipment; boating safety; engine tune-up; Engine disassembly and reassembly. Carburetor Fuel system; Pump, oil injection servicing Ignition system; electrical system; cooling system; Jet Drive, Impellor, reed block; engine specs; torque specs; maintenance and off-season storage; wiring diagrams. This manual is in PDF Format for Windows, Linux ,PDA and Mac consist of Separate chapters cover: Description and operation; safety; tuning; maintenance; troubleshooting; fuel and oil; ignition; engine; electrical; jet pump; control adjustments; wiring diagrams.