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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #41 ·
The 2006 Hawkeye 300 has two methods of killing the spark; Primary method, remove 12vdc from the red/wht wire of the CDI. Secondary method; connect the blk wire to ground. Assure there is 12v on the red/wht wire at the CDI unit in addition to disconnecting the blk wire.
Thanks 👍! I’m pretty sure this is an 06 so I’ll check those pins to the cdi and figure out what is the problem. I have done a decent amount of wiring so I probably messed something up
 

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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #42 ·
Today’s update: Thanks to latebird I was able to find the correct black wire that goes to the cdi and that fixed the no spark problem! I must have messed up something in the wiring so oh well 🤷‍♂️. Secondly, I was able to start it. I just had 1 carb on and I tested today without the supercharger on just to make life easier, and while it does need quite a bit of tuning, it does run pretty well. I also finished the cam gear cover and shaft seal because in order to finish testing I need to not have oil spray everywhere 🤣


Secondly, I have a question for all of you. Do 300 and 400 Hawkeyes, 500,570 and 800 sportsman’s have rev limiters ? With this new carb this engine revs much higher then it used to, and I am wondering if it really has a rev limiter since I’ve never heard a Polaris rev limiter and definitely think I would have hit a limiter by know if it had one.
 

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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #43 ·
So today I did some more NA testing, and I found that ( a long term problem has been it would try to drive at idle ) the idle it used to be set at was simply too high and that the wet clutch has been partially engaged at idle all these years! So now that that problem is out of the way, I moved on to test the rev limiter, and I found with just a single 27mm carb this engine will rev up to 7500rpm ( tested with a tiny tach) ... still couldn’t hit a rev limiter... as soon as I get the supercharger mounted I’ll re test the max rpm with both carbs. I don’t know how far I can rev this engine but I know by sound 7500rpm is higher then it used to rev with the stock carb.

I also got the shaft seal installed for the cam output shaft, and a wheel and the front bumper painted!

sorry that I haven’t started on mounting the supercharger yet, but I have a small gap of warm weather and I have to get all my painting done before it gets below 50*F again.
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Secondly, I have a question for all of you. Do 300 and 400 Hawkeyes, 500,570 and 800 sportsman’s have rev limiters ?
Yes, they all have rev limiters - the 300 Hawkeye's rev limiter is built into the speedo. The black wire connected to the CDI unit kills spark on every other stroke at a preset RPM - the RPM is read by the speedo from the yel/red wire off the alternator. Disconnect the black wire from the CDI box or disconnect the red/yel wire from the speedo and the rev limiter is defeated.
 

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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #45 ·
Yes, they all have rev limiters - the 300 Hawkeye's rev limiter is built into the speedo. The black wire connected to the CDI unit kills spark on every other stroke at a preset RPM - the RPM is read by the speedo from the yel/red wire off the alternator. Disconnect the black wire from the CDI box or disconnect the red/yel wire from the speedo and the rev limiter is defeated.
Ok..... that is very good to know.... thanks for this information, I will find out what is triggering the black wire to tell the cdi to always be on kill and then re test the rev limiter. Atleast I have a base line number of a safe rev before I add boost, because I know 55mm of carb and 15lbs of boost will overcome any regular timing reduction rev limit like most pit bikes have. So thank you very much for this info !
 

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04 Sportsman 700, 04 Scrambler 500, 04 trail touring 550 sled
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15lbs! You’re gonna run into a lot of issues lol. I expect to see some bent rods at the least.
 
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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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102 Posts
Discussion Starter · #49 ·
15lbs! You’re gonna run into a lot of issues lol. I expect to see some bent rods at the least.
We are only going to go to 15lbs of boost for stage 1. The end goal is to have a dual fuel system with m-1 methonal and run somewhere between 30-45lbs of boost. I already know of a company that can machine parts, so I’d send them a cad file of a rod and get a billet rod. I know the other problems would be headbolts stretching and blowing headgaskets and I know at some point I’d have problems with tuliping valves. So hopefully it goes ok on 15lbs of boost. I know from larger engines that a SBE setup will typically hold 18 lbs of boost, so hopefully the same rule applies for this engine.
 

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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #50 ·
Ok guys.... I was running into some issues with tuning the new carb setup and I didn’t really have the opportunity to weld a O2 sensor bung onto the exhaust and seeing exactly what my problem was, so I decided to pop the old carb on and see how well it runs. Good news is it runs good on the old carb and I was able to see what rpm the cvt engages, and if my oil cooler/filter was working and not leaking. Will post a video shortly.
 

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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #51 ·
Small update for everyone here... still no supercharger has been mounted. I’ve ran into some problems with sizing of clamps and random problems that you always overlook when starting a project. Anyways, I have a question for the old Polaris techs. I did a compression test and it came in at about 135psi, WITH NO decompression lever. The manual says it has 9.2:1 compression, and with the compression lever they say 90-120psi is acceptable.
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04 Sportsman 700, 04 Scrambler 500, 04 trail touring 550 sled
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My 700 makes 175 cranking. My 400 makes 135, my zero turn makes 145, and my 500 makes 90 (with decompression). It’s all relative, but anything above 110-120 without decompression is ok, but again you should check your manual.
 

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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #54 ·
Thanks for all the compression test imput guys! I haven’t tested many things with a compression tester so I don’t know an average yet, only other engine I know yet is my Apollo 125 with a claimed 8.8:1CR and it makes 155psi cold( I think it has a modified head/cam tho.
 

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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #55 ·
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Now for the blown Frankenstein quad update: I’m still waiting on parts to show up so I can actually get the supercharger mounted, but in the meantime I got it running NA with just a single lawn more carb, and it runs fantastic! I decided just to go with a single carb along with the supercharger as the supercharger draws air at a more frequent pulse then the intake valve opens, so I can get away with a smaller carb and be perfectly fine. I have gotten done more painting/restoring,wiring, and resembling the quad.
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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #56 ·
So today I began to peice together the blower setup and I actually got it to run under boost! The most I saw was 10lbs before the Bov opened and began to vent pressure. The engine did survive 10lbs without a problem so soon I’ll add dome pressure and see if I can get 15-20lbs out of it!
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So today I began to peice together the blower setup and I actually got it to run under boost! The most I saw was 10lbs before the Bov opened and began to vent pressure. The engine did survive 10lbs without a problem so soon I’ll add dome pressure and see if I can get 15-20lbs out of it! View attachment 173169
View attachment 173168
Yay, you finally cut the drive pulley shaft to length. (That was killing me.) LOL
How does it sound, n/a versus 10#? Any videos?
 

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2006 Hawkeye 300- 4x4 swapped, boosted, sportsman body swap
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Discussion Starter · #59 ·
Yay, you finally cut the drive pulley shaft to length. (That was killing me.) LOL
How does it sound, n/a versus 10#? Any videos?
Haha ikr that shaft was bothering me lol. There is a new video on joint performance YouTube channel. I’ll apologize in advance for the poor video, because I had no one else to record for me, and the engine sucks the carb dry in 4 seconds, and I have not yet made a fuel system that can deliver enough fuel lol
 
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