2006 Polaris Hawkeye 2x4/4x4 ATV Service & Repair Manual (P/N 9920206)

The Polaris service manual for the 2006 Hawkeye 2x4 and 4x4, P/N 9920206, covers scheduled maintenance, engine rebuilds, drivetrain repair, chassis service, and electrical diagnosis. Model-specific specifications identify A06LB27AA and A06LD27AA.

Searchable Service Chapters and Wiring Detail

Text search and bookmarks: Text search works across the service chapters, and embedded PDF bookmarks link to chapters and individual service topics. Labels within the full wiring diagram are not searchable. Its small connector identifiers and wire codes are readable with zooming.

Supplied as one printable, English-language 217-page PDF, including five notes pages and three blank pages within the total.

Hawkeye Engine, Drivetrain, and Electrical Coverage

• Engine repair: Step-by-step procedures for engine removal, cylinder-head service, piston inspection, crankcase disassembly, camshaft timing, and crankshaft end-play adjustment.

• Fuel system: Mikuni BST 34 carburetor disassembly, cleaning, inspection, float adjustment, leakage testing, and temperature- and altitude-specific jetting charts.

• CVT and transmission: Drive and driven clutch service, belt inspection, overheating diagnosis, shift-linkage checks, and internal transmission disassembly and reassembly.

• Final drive: Centralized Hilliard front gearcase overhaul and AWD diagnosis for 4x4 models, plus hub bearings, prop shafts, U-joints, and CV joint service.

• Brakes and suspension: Hydraulic brake bleeding, caliper rebuilding, disc inspection, MacPherson strut replacement, steering-post service, and independent rear suspension work.

• Electrical troubleshooting: Electronic Throttle Control (ETC), CDI, stator, charging-system and starter tests, with diagnostic flowcharts and the vehicle wiring diagram.

This manual suits technicians familiar with ATV service; the CVT chapter specifically calls for trained Polaris Master Service Dealer technicians and factory-authorized tools.

Engine Rebuilds and Lubrication Diagnosis

The engine chapter covers the ES30PFE / ES300PFE010 from cylinder-head inspection through bottom-end reassembly. Valve-seat reconditioning, cylinder honing, piston-ring inspection, counterbalancer setup, and the multi-stage cylinder-head bolt torque-and-angle sequence are documented.

Job planning: Separate engine and transmission removal procedures show how the transmission can be removed independently, helping establish the dismantling required before work begins. Crankshaft inspection and end-play adjustment are covered, but the crankshaft itself is replaced as an assembly rather than rebuilt internally.

The Oil Flow Diagram traces lubrication through the engine, while the oil-pressure test and breather/oil-separator information support lubrication diagnosis. The flywheel-removal warning identifies a vulnerable crankshaft oil-passage plunge joint: damage there can cause oil-pressure loss and severe engine damage.

Carburetor Service and Fuel Delivery

The BST 34 Carburetor Exploded Views identify the diaphragm, jets, needle valve, and float components. Fuel-starvation, rich-mixture, and poor-idle troubleshooting sections connect symptoms with the relevant circuits and adjustments.

Needle-and-seat leakage testing and fuel-level checks go beyond routine cleaning. The manual also identifies the factory-sealed pilot circuit as work for a certified repair shop.

Clutch, Transmission, and AWD Repair

CVT service: Belt tolerances, roller and sheave inspection, clutch charts, and driven-clutch rebuilding procedures are accompanied by special-tool references, including Drive Clutch Holder PA-47478 and Clutch Compression Tool 8700220. Internal transmission coverage includes gears, engagement dogs, the reverse chain, shift drum, and shift fork.

4x4 fault finding: AWD diagnosis combines coil testing with armature-plate wear and roller-cage inspection, helping distinguish electrical engagement faults from mechanical problems. The gearcase cutaway explains how coil seating relative to the U-shaped insert affects pole gap and AWD engagement.

Brake, Steering, and Suspension Work

Hydraulic brake procedures cover fluid changes, bleeding, master-cylinder replacement, caliper inspection and rebuilding, and disc thickness/runout checks. Chassis coverage extends to steering bearings, ball joints, front struts, rear control arms, and CV boots.

Working on ATVs carries inherent risks; follow the manual’s vehicle-support precautions and brake-system checks before returning the machine to service.

Electrical Tests and Circuit Tracing

The Starter System Testing Flow Chart, Charging System Testing chart, and Ignition System Troubleshooting chart support circuit diagnosis alongside the wiring diagram. Tests cover CDI output, ignition-coil resistance, stator function, speed-sensor signals, and starter-circuit voltage drop.

Starter service includes brush and armature inspection. The installation notes explain how mounting alignment affects bendix engagement; incorrect alignment can cause binding and starter damage.

A Preview of Valve and AWD Test Specifications

The engine service data specifies intake and exhaust valve clearance at .006 in. (0.15 mm), alongside camshaft measurements and cylinder-head inspection limits.

For the 4x4 front gearcase coil, the manual gives a resistance range of 21.6–23.9 ohms at 68°F (20°C). This electrical check accompanies the mechanical inspection of the AWD engagement components.