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Polaris 1996 Sportsman 400, Service Manual

The Polaris 1996 Sportsman 400 Service Manual is the essential guide for maintaining and repairing your ATV. Download this manual for free from manualshive.com to access detailed instructions and diagrams to keep your vehicle running smoothly. Ensure optimal performance with this comprehensive manual at your fingertips.

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Summary of Contents for 1996 Sportsman 400

Page 1: ...irement s Troubleshooting instruments Starting the engine Starting diffi culties Engine is difficult to start Engine starting system Charging system Ignition system Electronic throttle control 1 Expen...

Page 2: ...buretor tests and adj ustments Throttle cable replacemen t CHAPTE R SEVEN COOLING SYSTEMS Polaris variable transmission PVT air cooling system Eng ine cooling system Safety precauti ons Hoses and hose...

Page 3: ...SUSPENSION AND STEERING Front wheel Front hub Front strut cartridge and spring Front strut spindle Control arm CHAPTER THIRTEEN REAR SUSPENSION Rear wheels Tire changing and tirerepairs Shock absorbe...

Page 4: ...retor Sportsman 500 H G models Cleaning and inspection Carburetor tests and adjustments Drive belt Driven pulley 200 3 models bui lt after 07 08102 INDEX WIRING DIAGRAMS 382 Front master cylinder Rear...

Page 5: ...lant Grease Item Engine all Transmission all Front gear case all years Front hubs Coolant Lubricant or fluid type Polaris Premium 4 Synthetic 10W 4Q or 10W 40 motor all Polaris synthetic gear case 011...

Page 6: ...1997 1998 2001 2002 on Gap 1996 1998 1999 2000 2001 on Idle sp eed 1996 1988 2001 on 1997 2000 Carburetor pilot air screw 34 mm 1996 1997 1998 1999 2000 2001 on 400 ee Carburetor pilot air screw 40 m...

Page 7: ...ehicle weight dry Table 4 lists decimal and metric equivalents Tab le 5 lists general torque specifications Tab le 6 lists conversion tables Ta ble 7 lists technical abbreviations Table 8 lists metric...

Page 8: ...If a few rules of com mon sense and safety arc observed many safe hours can be enjoyed servicing the ATY Ignor ing these CHAPTER ONE rules can injure someone wor king on the vehicle or dam age the AT...

Page 9: ...ailable for home and shop lise most arc poisonous and extremely flammable To prevent chemical overexposure vapor buildup tire and sc 3 rious injury observe all manufact urer s direct ions and warn ing...

Page 10: ...to put oot Use a Class B BC or AIlC fire extinguisher to smother the names and put the fire out 9 Always tum the engine off before refu eling Usc a wide mouth funnel to prevent spilling gasoline onto...

Page 11: ...Some operations require the usc of a hydraulic press If a press is not available it is wiser to have these operatio ns performed by a shop equipped for such work rather than to try to do the job your...

Page 12: ...e usc an accurat e torque wrench de scribed in this chapter together with the torqu e specifica tions listed at the end of most chapters Torque specifications throu ghout this manu al nrc given in New...

Page 13: ...igure 5 nominal diameter D and distance between thread crests T The numbers 8 x 7 1 25 1 30 identifi es a typical bolt which would in dicate that the bolt has a nominal diameter of8 mm the distance be...

Page 14: ...rand a fastenerto provide a smooth bear ing surface This allows the fastener to be turned easily with a tool NOTE As much care should be given to the selection and purchase ofwashers as that gi ven to...

Page 15: ...ral based including petroleum bases natural based vege table and animal bases syn thetic based or emu lsions mixtures Grease is oil to which a thickening base has been added so that the end prod uct i...

Page 16: ...able at motorcycle and automotive sup plies stores and major hardware stores Moisture in the air causes the RTV to cure Al ways place the cap on the tube as soon as possible C HAPTER ONE whe n using R...

Page 17: ...numbers The serial number locations arc as fol lows I Model and YIN number Figure 9 is stamped on the left lower frame rail near the rear portion of the front A arm mount On some models a decal with t...

Page 18: ...re to workwithand easy to clean The initial cost of good quality tools may be more but they are moreeconomical in the long run Do not try to buy everything in all sizes in the beginning buy a few at a...

Page 19: ...are speedy and work best in areas with limited overhead ac cess Their wide flat jaws make them unstable for situations where the bolt or nut is located in a bore or close to the edge of a casting Thes...

Page 20: ...socket Impact Driver This tool might have been designed with the ATV mechanic in mind This tool makes removal of fas teners easy and eliminates damage to bolts and screw slots Impact drivers Figure 19...

Page 21: ...ug gap Flat gauges arc used for other measure ments Feeler gauges are also designed for special ized uses For example the end of a gauge can be small and angled to facilitate checking valve clear ance...

Page 22: ...micrometers lise fixed anv ils Some micrometers use the same frame with inter changeable anvils of different lengths This allows the installation of the correct length an vil tor a par ticular job Fo...

Page 23: ...o the right of the decimal point Use it when reading dec imals from one tenth to one one thousandth of an Inch or millimeter It Is not a con version chart for example 0 001 in Is not equal to 0 001 mm...

Page 24: ...0003 In Total readi ng 0 1683 In Sleeve Th imble I Read the sleeve line to find the largest numher visible each sleeve number mark equals 0 100 inch 2 Count the number of sleeve marks visible be tween...

Page 25: ...he sleeve line read the vernier scale in Step 3 3 Read the vernier scale to find which vernier mark lines up with the one thimble mark The num ber of that vernier mark is the number of ten thousa ndth...

Page 26: ...ate the decimal amount between the lines For an accurate reading a metric vernier microm eter must be used 4 Adding the micrometer readi ngs in Steps I 2 and 3 gives the actual measurement etric verni...

Page 27: ...ck a 0 1 in 0 25 mm micrometer per form the following a Tum the spindle until the spindle contacts the anvil If the micrometer has a ratchet stop use it to ensure that the proper amount ofpressure is...

Page 28: ...curacy Check previously described in this section Cylinder Bore Gauge The cylinderboregauge is a very specialized pre cision tool comprising of a dial indicator handle anda number ofdifferent length a...

Page 29: ...leshooting Figure 32 The voltage application is used to indicate the voltage applied or available to various electr ical com ponents The ohmm eter portion of the meter is used to check for continuity...

Page 30: ...ohmmeter Becau se resistance generally increases with tem perature perform resistance tests with the compo nent or circuit at room temperature Resistanc e tests CHAPTER O NE on a hot component will i...

Page 31: ...oosen it First apply pene trating oil such as Liquid Wrench or WD 40 avail ab le at hardware or auto supply stores Apply it liberally and let it penetrate for 10 I5 minutes Rap the fastener several ti...

Page 32: ...intained by proper lubrication and mai ntenance If a bearing is damaged it must be replaced imme diately However when installing a new bearing care should be taken to prevent damage to the new 2 Drill...

Page 33: ...aring removal is withahydraulicpress However certain procedures must be followed or damagemay occurto thebear ing shaft or bearing housing Note the following when using a press 2 Whenusing a hamIller...

Page 34: ...s may cause bearing damage Instead the bearing should be heated before installation Note the fnlJowing a Secure the shaft so that it is ready for bearing installation b Clean all residue from the bear...

Page 35: ...possible Chilling a bearing will slightly reduce its outside di ameter while the heated bearing housing as sembly is slightly larger due to heat expansion This will make bearing installa tion much eas...

Page 36: ...areas where facto ries arc liable to emit corrosive fumes Also avoid buildings ncar large bodies of salt water 4 Select an area where there is minimum risk of fire theft or vandalism Check with the in...

Page 37: ...sitioned against the exhaust pipe 5 Before starting the engine remove the spark plug and tum the engine over a few times to blow out the excess storage oil Place a rag over the cylin der head openings...

Page 38: ...2 0 15625 3 96875 21 32 0 65625 16 66875 11 64 0 171875 4 36562 43 64 0 671875 17 06562 3 16 0 1875 4 76250 11 16 0 6875 17 46250 13 64 0 203125 5 15937 45 64 0 703125 17 85937 7 32 0 21875 5 55625 23...

Page 39: ...rs kilograms Volume Cub ic inches Cubic centimeters Temperature Fahrenheit Centigrade Weight Ounces Poun ds Grams Kilograms 25 4 Millimeter 2 54 Centimeter 1 609 Kilometer 0 3048 Meter 0 03937 Inches...

Page 40: ...It lb gal H1A hp In in Ib 1 0 kg kgm km kPa L m MAG ml mm Nom 0 0 oz psi PTO PVT pt qt rpm VST After bottom dead center After top dead center Before bottom dead center Bottom dead center Before top de...

Page 41: ...xl 25 10 xl 50 11 x 1 50 12 x 1 50 12 x 1 75 Drill equivalent No 39 3 32 No 30 1 8 No 19 No 20 No 9 16 64 J 17 64 5 16 5 16 11 32 R 3 8 13 32 13 32 Decimal raction 0 0995 0 0937 0 1285 0 125 0 166 0...

Page 42: ...ormed at home On the other hand be realis tic and do not start procedures that are beyond the experience and equipment on hand Many service departments i l not lake work that involves the re assembly...

Page 43: ...their lise STAIn iNG TI lE ENGI NE Use the following outline as a guide for basic starting procedures Jn alt cases make sure that there is an adequate supply nf fuel in the lank Sta rting a Cold Eugin...

Page 44: ...er I Make sure the choke toggle lever is in the correct position Move the toggle lever to the ON position F igure 6 for a cold engine and to the full OFF po sition A Figure 4 for a warm or hot engine...

Page 45: ...th a gauge all this engine due to the compression release mecha nism within he camshaft d Install thc spark plug and cap Engine Fail s to Start Spark Test Perform the following spark test to determine...

Page 46: ...pter NOTE Ifthe engine backfires during starting attempts the ignition timing may be incorrect Refer 10 Ignition Timing in Chapter Three fo r more information ENGINE IS DIFFICULT TO START The followin...

Page 47: ...iston rings a Worn piston rings b Damaged piston rings c Piston seizure or piston damage 3 Crankcase and crankshaft a Seized connecting rod b Damaged crankcase 41 c Damaged oil seals Poor Idle Speed P...

Page 48: ...t switch b Start switch c Engine auxi liary shutoff switch 4 Disconnect the red white electrical connector from the starter solenoid Connect a vo ltmeter black test lead to ground and the red test lea...

Page 49: ...Make sure the fuel tank has an adequate supply of fresh gasoline and is full 43 6 Make sure the spark plug cable is properly con nected to the spark plug 7 Remove the spark plug and examine it as de...

Page 50: ...44 CHAI TER TWO IGNITION SYSTEM 2 7 1 Flywheel 2 Stator colis 3 Trigger coil 4 Seal 5 Stator plate 6 Bushing 7 O ring B COl unll 9 Ignition high tension coil 10 Spark plug cap 11 Spark plug 9...

Page 51: ...ally throttle cable tension holds the ETC switch in the open position Ifa mechanical fa ilure occurs in the throttle mechanism and cable tension is lost the switch contacts close This grounds the COl...

Page 52: ...rect ignition timing 2 Engine compression system a Cylinder head gasket leakage b Heavy carbon buildup in combustion cham be r 3 Engine cooling system a Improper spark plug heat range b Cooling system...

Page 53: ...a too hot spark plug can cause pinging 47 Refer to Spark Plug Ileal Range in Chapter Three Check also for excessive carbon buildup in the combustion chamber or a defective ignition system CD unit II...

Page 54: ...breather tube indicates worn piston rings 7 A cylinder with 10 1 cylinder Icakdown requires further service 8 Install the spark plug and the air filter assembly POWER TRAIN Th e following items provid...

Page 55: ...disc 6 Air in brake lines Leaking Transmission I Loose bolts 2 Damaged gasket seal 3 Damaged seals 4 Cracked or broken case and or cover Drive Clutch E u ga es Before Specified Engagemen t RPM I Worn...

Page 56: ...c t ca liper alignment IBrake chatter I loose caliper mounting bolts I Loose front axle nut and or clamps Worn wh eel bearings Damaged hub Restricted brake hydraulic line Contaminated brake pads Check...

Page 57: ...aliper mounting bolts f Damaged caliperts g Cracked wheel flange or bosses where the brake disc mounts to the hub flange 2 Front shock absorber noise a Cracked or broken shock spring s b Damage shock...

Page 58: ...white and white red Charge coil 1996 1998 Yellow to yellowlbrown Yellow red to yellowlbrown Charge coil 1999 on Yellow to yellow red Yellow to ground Ignition coil Primary resistance Secondary resista...

Page 59: ...ditions high humidity partial watersubmersion muddiness etc pcrfonn the services more frequently Most ofthe service procedures in the schedule are described in this chapter however those that re quire...

Page 60: ...bar from side to side and check for steering play Check that the control cables arc properly routed and do not interfere with the han dlebar or the handlebar controls 5 Check the throttle operation Op...

Page 61: ...cifica tions listed ill Table 2 arefor the original tires If different tires have been installed fo llow the tire pressure recommenda tions specified by the tire monufac turcr NOTE After checking and...

Page 62: ...a bat tel If electrolyte ge ts into the eyes call a physician immediately Force the eyes open 11 1 flood them with cool clean water fo r approximately 15 minutes Rim Inspection BATTE RY Safety Precau...

Page 63: ...he rear frame resultin g in corrosion 3 Make sure all cell caps are in place and are tight tighten if necessary 4 Ifthe electrolyte level is correct reinsta ll the bat tery Battery Removal Installatio...

Page 64: ...op the battery has been sutTering from overcharging or overheating 3 Check the battery terminal bolts spacers and nuts for corrosion deterioration or damage Clean parts thoroughly with a baking soda a...

Page 65: ...g water 0 the cells will lower the specific gravity density of the electrolyte Af ter adding H ater charge the battery or 15 20 minutes at a rate high enough to cause vigorous gas sing Draw sufficient...

Page 66: ...e vehicle as de scribed in this chapter 2 Connect the positi ve charge r lead to the positive battery terminal and the negative charger lead to the negative battery terminal 3 Remove all fill vent cap...

Page 67: ...ordielectric grease to the electrical ter minals of the battery to retard corrosion PERIODIC L UBRICATlO l Perform the services listed in this section at the maintenance intervals listed in Table I R...

Page 68: ...or oil collection Do not combine other flu ids with motor oil to be recycled To locate a recycler contact the Ameri can Petroleum Institute AP I at www reeycleoil org NOTE Warming the engine allows th...

Page 69: ...maintaina leak free seal d Install a new gasket onthe drain plug and in stall the drain plug Tighten to the torque specification listed in Table s 10 To replace the oil filter perform the following a...

Page 70: ...il Pressu re Test Usc this procedure to check the engine oil pres sure after reassembling the engine or when trouble shooting the lubrication system An oil pressure gauge and 1 8 NPT oil pressure gaug...

Page 71: ...27 4 f necessary add the correct type of oil Table 3 to bring the level withindie knurled section ofthe dipstick 5 lnstall the oil fill cap dipstick Trans mission O il Change Polaris reco mmends the u...

Page 72: ...oil level as descrihed in this chapter Adjust the oil level if necessary WARNING Contact with oil may cause cancer lIash both hands thoroughly with soap and water as soon as possible af ter handling o...

Page 73: ...ed Refer to Chapter Ten 9 Install a new gasket on the drain plug 10 Install the drain plug and its gasket Tighten the drain plug to the torque specification listed in Table 5 II Insert a funnel into t...

Page 74: ...o trickle out with the hub in this position the oil leve l is correct If not proceed to Step 3 CAUTION Do not overfill the mnt hub and do notforce the oil into the hub as the in ternal seals will be d...

Page 75: ...emove thc fill check plug Figure 40 R Inspect the hubcap O ring seals Figure 44 for nicks cuts anddeterioration Replace asnecessary 9 Install the hubcap and lap il into place until it is completely se...

Page 76: ...cables from the carburetor assembly and try at the opp osite end of thc cable NOTE Place a shop cloth at the end of the ca bles 0 catch the oil as it runs Ollt 7 Disconncct the lubricator 8 Appl y a l...

Page 77: ...ediately with soapy water and thoroughly rinse it offwuh clean water WARNING Use brakefluid clearly marked DOT3 from II sealed container Other Opes may vaporize and cause brakefailure Always use the s...

Page 78: ...e ground Block the front wheels so the vehicle can not roll in either direction 3 Remove the bolts and washers sec uring the drive chain guard and remove the ehain guard 4 At the rear brake caliper lo...

Page 79: ...andlebar from side to side in the full turning range If the idle speed increases the throt tic cable free play must be increased or the throttle cable is routed incorrectly 13 Check for smooth throttl...

Page 80: ...element 13 Figure 55 from the airbox 6 Place a clean shop cloth into the opening in the air filter air box to prevent the entry of debris 7 Slide off the foam pre filter or pre fi lter sleeve A Figur...

Page 81: ...sitioned correctly within the rear portion of the front fender B Figure 60 17 Check the air box sediment drain as follows a At the rear of the air box place a rag under the drain cap and remove it Fig...

Page 82: ...Install the front fender cover as described in Chapter Fiftecn Coolant C ha nge Drain and refill the cooling system at the interval listed in Table I It is sometimes necessary to drain the coolant fr...

Page 83: ...nt from the pump and hoses 8 Rock the ATV from side to side to drain any re sidual coo lant from the cooling system Correctly dispose of the coo lant NOTE If the coo lant is dirt place a different dra...

Page 84: ...ec urely NOTE Fill the cooling system slovvly so the coolant can expel the air within the radiator and engine 19 Rock the ATV about 20 to the left and then to the right several times This will help bl...

Page 85: ...y cable as de scribed in this chapter 3 Tum the fuel valve to the OFF position 4 Place several cloths underthe fuel filter asgaso line still present in the fuel line will drain out once the fuel filte...

Page 86: ...ide to side and notice the following a rf there is appreciable looseness at the tie rod ends the ends may be worn b Observe the joint between the lower end of the stru t and the A ann Noticeable loose...

Page 87: ...g the bearings and sea ls I Support the vehicle with both front whee ls otT the ground Block the rear wheels so the vehicle cannot roll in either direction 2 Tum both whee ls by hand The wheels shou l...

Page 88: ...System Check all of the switches for proper operation Refer 10 Chapter Eleven Electrical Connectors Inspect the higb tension lead to the spark plug Figure 76 for cracks and breaks in the insulation an...

Page 89: ...ake it easier to rotate the engine Place a piece of duct tape over the spark plug hole to pre vent the entry of deb ris 5 Remove the screws securing the cylinder head cover Figure 77 and remo ve the c...

Page 90: ...es perform the following a Clean the gasket surfaces of the cylinder head and the cover Inslall a new gasket to the cyl inder head cover Figure 83 b Install the cylinder head cover and tighten the ret...

Page 91: ...knut was tightened Re adjust the valve clearance if necessary 8 Clean the gasket surfaces of the cylinder head and cover then install a new gas ket to the cy linder head cover Figure 83 9 Install the...

Page 92: ...un d to the threads ofthe spark plug before installing it Do not lise engi ne oil on the plug threads C uTiON The cylinder head is aluminum and cross threading of he spark plug call eas ily damage it...

Page 93: ...ly film overthe firing endandacarbon layer over the entire nose The electrodes are not worn Common causes forthis condition arc I Incorrect air fuel mixture 2 Low idle speed or prolonged idling 3 Igni...

Page 94: ...y leaded gasoline Can be cleaned OVERHEATING Identif ied by a white or light gray insulator with small black or gray brown spots with bluish burnt appearance of electrodes Caused by engine overheating...

Page 95: ...eet and cloth ing awa v from the engine helt and drive chains 6 Start the engine allow it to idle for approxi mately 10 15 seconds then increase the engin e speed to the ignition timing speed rpm list...

Page 96: ...speed Turning the pilot air screw clock wise reduces the amo unt of air and richens the mixture The pilot air screw is preset by the manufacturer The following procedure is to be used only after the...

Page 97: ...flation pressure Check whee l rim condition Check brake fluid level add fluid if necessary Check brake lever operation and travel Check tightne ss of nuts bolts and fasteners Check Iuellevel J n fuel...

Page 98: ...Remove th e drain plug on muffler and drain out any residue Every twenty four months or afte r 200 hours of operation All of the above checks plus the following Change brake fluid Check tightness of f...

Page 99: ...screen and fitting 20 Valve adjuster locknuts 6 7 53 62 Wheel lug nuts Front 21 Rear 21 Ta ble 6 MAINTENANCE AN D T UNE UP SPECIFICATIONS ft lb 14 14 15 15 15 Item Disc brake pad thickness wear limit...

Page 100: ...Have all the necessary hand and special tools available Make sure the work area is clean and well lit Identify and store individual parts and assemblies in appropriate storage containers Figure I Refe...

Page 101: ...n ks haft ca using it to rotate 3 COMPRESSION Intake valve closes and piston rises In cyli nder compressing air fuel mixture Carburetor 4 INTAKE Intake valve opens 8S piston begins downward drawing ai...

Page 102: ...oil cool ant pum p drive gears cam chain and drive sprockets Oil pump serv ice is covered in Chapter Five Refer to Chapter Three to service the engine oil and the oil filter and to check the oil press...

Page 103: ...E GIr E TOP END EXHAUST SYSTEM 97 1 NUl 2 Washer 3 Rubber cushion 4 Washer 5 Collar 6 Mounting bracket 7 Boll 8 Drain boll 9 Muffler 10 Spring 11 Exhaust pipe 12 Heat shield 13 Heal shield 14 Gasket...

Page 104: ...ning 6 Remove the nut and washer F igure 9 securing the exhaust pipe to the frame mount ing bracket 7 Disengage the exhaust pipe from the fitting 8 Lift up on the rear portion of the exhaust pipe un t...

Page 105: ...COVER Remnval Installatton I Place the ATV on a level surface and set the parking brake Block the wheels to keep it from roil ing in either direction 2 Remove the scat and front fender as described in...

Page 106: ...rarms d Wiggle all four rocker arms Ihere should be tree play indicating that all four valves are closed This indicates that the pislon is at lop dead center TOe on the compress ion stroke and all fou...

Page 107: ...bolts Figure 23 and tighten in a crisscross pattern to the torque value listed in Table 3 5 If loosened or removed tighten the rocker shaft retaining screw F igure 22 securely 6 Adjust valve clearance...

Page 108: ...he shaft from the sup port Figure 29 9 Inspect rocker ann bores Figure 30 and the shaft support bore Figure 31 for wear or scoring 10 Measure the rocker ann bore diameter with a snap gauge Figure 32 R...

Page 109: ...mhly in in this chapter When the piston is at TDe on the compression stroke the sprock et alignment pin Figu re 35 will be located at the top of th e camsh aft 3 Remove the coo lant reservoir A Figure...

Page 110: ...ck 9 Place a clean shop cloth in the cavity below the cam sprocket then remove the three sprocket mounting bolts Figure 42 10 Hold onto the sprocket then slide the camshaft in and away from the sprock...

Page 111: ...scoring 5 Measure each camshaft bearing journal Figure 46 with a micrometer 6 If the bearing journals are severely worn or dam aged check the bearing journals in the cylinder head They should not be s...

Page 112: ...ccompressionreleasernechanism lo cated within the center of the camshaft can be in spected without removing the camshaft from the engine 1 Twist therelease mechanism inside the camshaft and observe th...

Page 113: ...allation NOTE T o install the automatic compression release mechanism Figure 53 the actuator hall Figure 51 must be held out r necessary u e a small magnet 10 hold the actuator hall out while installi...

Page 114: ...erly mesh the driven sprocket with the cam shaft cha in as follows a Pull up on the camshaft cha in and make sure it is properly meshed with the crankshaft drive sprocket b Align the driven sprocket t...

Page 115: ...crankcase projection B Figure 58 b The camshaft sprocket drive pin A Figure 62 will be straight up as shown c The camshaft sprocket dots will be facing up B Figure 62 10 When thecams haft timing iscor...

Page 116: ...requently There fore during Stcp 14 reference the limingmarks on the sprockets not the lVO plated can shaft links 14 Rotate the engine crankshaft two or more revo lutions and recheck alignment of the...

Page 117: ...k mating surfaces 2 Before removing the valves remove all carbon deposits from the combustion chamber A Figure 71 and valve ports with a wire brush Use a blunt screwdriver orsimilar scraperandbe caref...

Page 118: ...re 78 in the cylinder block 2 Position the new gasket B Figure 78 onto the cylinder block and over the locating dowels Make sure allcoolant and bolt holes are aligned correctly 3 Position the cylinder...

Page 119: ...180 1 2 tum e Tighten to 15 Nom II ft lb f Tighten each ofthe four bolts exactly 90 1 4 tum g Finally tighten each of the four bolts exactly 90 114 tum more 9 Tighten the two small 6 rnrn bolts 8 Fig...

Page 120: ...the valve spring retainerand the valve head CAUTION Toavoid loss ofspring tension do 1101 compress the spring any more than necessary to remove the valve keepers 2 Tighten valve spring compressor unti...

Page 121: ...i able proceed to Step 6 5 Measure the valve guide inner diameter with a small hole gauge Figure 89 Measure at the top center and bottom positions Then measure the small hole gauge and check against...

Page 122: ...alve burning or overheating Check Valve sticking Cyli nder head warped Valve seat distorted Valve clearance Incorrect Incorrect valve spring Valve spring worn Worn valve seat Carbon buildup In engine...

Page 123: ...e 4 If the seat width exceeds the specifications recondition the scats as described in this chapter f Clean all marking compound from the seats and valves Valve Installation I Clean the end of the val...

Page 124: ...Guide Replacement Valve Lap ping Valve lapping is a simple operation that can re store the valve sea l without machining if the amount of wear or distortion is not too great Perform this procedure aft...

Page 125: ...s and two scaling washers at each end of the oil pipe Re move the oil pipe and place in a reclosable plastic bag along with the banjo bolts and sealing washers to keep them clean 3 Repeat Step 2 for t...

Page 126: ...iston skirt from damage This fixture Fig ure 11I3 may bepurchased or fabricated from wood Inspection A bore gauge and micrometer are requiredto ac curately measure the cylinder bore Ifthese tools are...

Page 127: ...n and must be re washed When the cylinder bore is thoroughly clean lubricate the cylinder bore with clean engine oil to prevent it from rusting CAUTION A combination ofsoap and water is the only solut...

Page 128: ...suppliers I Clean the crankcase mating surface of all gasket residue Fi gure II I 2 Check that the top and bottom of the cylinder hlock surfaces are clean of all gasket residue 3 If removed install th...

Page 129: ...r block dow n onto the piston until it lightly bottoms out on the ring com pressor Fign re 116 13 Slowly and carefully slide the cylinder block down past the piston rings then remove the piston ring c...

Page 130: ...banjo boll and new scaling washers Figure 119 at each end of the oil pipe Refer to Figure 120 and Figure 121 Tighten the banjo bolls to the torque specification listed in Table 3 23 Insert the camsha...

Page 131: ...damaging the connecting rod The piston must be supported when eitherpushing or pulling the pin i OlII the pis ton pill bore Be sure that lateral loads are not transmitted to the lower connecting rod b...

Page 132: ...ntly de formed Replace the piston 5 Check the oil control holes in the piston Figu re 129 for carbon or oil sludge buildup Clean the holes with wire and blow out with compresse d air 6 Check the pisto...

Page 133: ...the connecting rod Slow ly rotate the piston pin and check for ra dial play Figure 133 4 Oil the piston pin and install it illthe piston Check the piston pin for excessive play Figure 134 5 Replace th...

Page 134: ...he piston pin borc groove 3 Slide the piston pin into the piston until its end is fl ush with the piston pin hoss Figure 134 4 Place a clean shop cloth A Figure 139 into the crankcase cavity to catch...

Page 135: ...NOTE Store the old rings in he order ill which they are removed 2 Remove the compression rings with a ring ex pandertool Figure 143 or by spreading Olering ends by hand and lifting the rings up evenl...

Page 136: ...E lnstall thr piston rillgs jirst the bot tom then the middle then tire lop ring by carefully spreading the ends by hand Figure 44 IIl1d slipping the rings Ol er the top of the piston Re member that t...

Page 137: ...ain failure do 1I0t cut and then reinstall this type ofchain In stall 01 V J n ell continuous closed loop chain Removal I Rem ove the cylinder head cover and rocker arm asse mbly as described in this...

Page 138: ...solvent and thoroughly dry 2 Place the chain on a flat surface and pull the chain tight with no slack between the pins exerting approximately 4 53 kg 10 lb force 3 Measure the length of any 20 pitch...

Page 139: ...0 11 nter clockwise 10 lighten the nut 6 Inspect the slotted nut ll Figure 157 for thread damage Replace if necessary 7 Check the WoodruITkey and the crankshaft key slot for wear or damage Replace th...

Page 140: ...s chapter Normal wear CHA PTER FOUR Excessive wear BREAK IN I IWCEDURE Ift he piston rings werereplaced a new piston in stalled the cy linder rehored or honed break the en gine in as though itwere new...

Page 141: ...4 ENGINE TOP END SPECIFICATIONS Item Rocker arm outside dia meter Rocker arm shaft outer diameter Rocker arm to shaft clearance Camshaft Lobe height Intake and exhaust Journal outside diameter Both s...

Page 142: ...1 656 Yellow paint mark 42 0 40 0 1 654 1 575 Cylinder block Bore 91 988 92 009 3 6216 3 6224 Bore limit 0 5 0 020 Taper 0 050 0 0020 Out of round 0 050 0 0020 Top surface warp 0 050 0 0020 Piston Out...

Page 143: ...erhaul Before removing the eng ine and disassembling the crankcase degrease the engine and frame Have all the necessary hand and special tools ava ilable Make sure the work area is clean and well lit...

Page 144: ...4 Disconnect the negative battery cable as de scribed in Chapter Three Secure the cable so it will not accidenta lly make contact with the battery ter minal 5 Drain theengine coolantas described in C...

Page 145: ...e 22 Remove the bolts securing the oil tank A Fig ure 5 Remove the oil tank and store it in the up right position 23 Remove the bolt s securing the coolant reser voir 13 Figure 5 Move thc coolant rese...

Page 146: ...hen remove the engine from the right side Installation l Install the engine onto the frame from the right side 2 Install the rear engine mou nt washer and nut loosely before inserting it into the slot...

Page 147: ...he lower fitting B figure 4 d Refer to Chapter Three and install the oil fil ter and refill the engine with oil e Refer to Chapter Nine and adjust the trans mission shift linkage f Check and adjust th...

Page 148: ...l Tighten the center bolt and remove the en gine flywheel from the crankshaft NOTE Do not lose the thrust washer located between the electric starter drive and the crankcase 8 Remove the electric star...

Page 149: ...tall the stator plate making sure Ihe previ ously affixed timing marks are aligned Be sure the stator is fully seated and tighten the retaining bolts to the torque listed in Table I 6 Seal the stator...

Page 150: ...ng and assembling 6 Carefully lift the starter pulle y and rope from the housing Make sure the recoi l spring rema ins in the starter housing 7 Unwind and remove the rope from the starter pulley if re...

Page 151: ...lt 13 14 15 16 17 A B a Tie a secure knotat one end of the rope and insert the other end through the hole A Figure 26 b Pull the rope through the pulley until the knot seats firmly in the pocket nf th...

Page 152: ...w l spring Figure 28 12 Install the paw l as shnwn in Figure 29 13 Install the friction plate and spring Figure 30 with eac h end ofthe spring located on the dri ve side ofthe ratchet 14 Install the s...

Page 153: ...nd punch holes 10 correspond with each bolt location After removal insert the holts in their appropriate locu tions Leave cable clamps on their re spective holts 5 Loosen the ten crankcase mounting bo...

Page 154: ...p shaft while tightening the center bolt to help during separation I I Insert a small drift into the right crankcase openin g and tap on the end of the balancer shan to ensure the balancer shaft stays...

Page 155: ...e Keep the shims with the shall as they must be reins talled 17 If so equipped remove the shim C Figure 36 from the end of the cra nkshaft I8A If a press is available perform the follow ing CAUTION Pl...

Page 156: ...readed holes in both crankcase halves for thread damage dirt or oil buildup If nec essary clean or repair the threads with a suitable size metric tap Coat the tap threads with kerosene or an aluminum...

Page 157: ...ted during re moval over the crankshaft F igure 50 and onto the crankcase mounting bore 6 Place a suitable size socket or bearing driver over the seal Drive the seat into its mounting bore Figure 51 u...

Page 158: ...Dowel pin 3 Crankcase half assembly 4 Dowe l pin 5 Bearing 6 Bolt 7 O ring 8 Mechanical seal water pump 9 Oil seal 10 Drain plu g 11 Gasket 12 Boll 13 Beari ng 14 Bearing 15 011 hose union 16 One way...

Page 159: ...on hand to be able to quickly rep lace the bearings wh ile the cra nkcas e is hot NOTE Prior to removing the right side crankcase main bearings the seal must be removed b Before heating the crankcases...

Page 160: ...gs by driving 011 their inner race Install the bearing s until it seats completely in its mounting bore 2B To replace bearings with a press a Remove the right side seal as described in this chapter b...

Page 161: ...caseseal mounting bore 3 Place a suitable size socket over the mechanical seal Drive the mechanicalsealoutofthe crankcase 4 Insert a scribe through the crankcase weep hole Figure 58 to ensure the hole...

Page 162: ...nd Float Measurement and Shim Selection in this cha pter Th is will deter mine the correct thickn ess of shims to install on the water pump shall crankshaft and bal ance shaft CAUTION The special cran...

Page 163: ...ENGINE LOWER END 157 II...

Page 164: ...otate the crankshaft so the timing mark Figure 79 is facing in the direction of the balance shaft 8 Install the balance shaft part way into the left crankcase CAUTION Improper alignment of the balance...

Page 165: ...ENGINE LOWER END 159...

Page 166: ...owels onto the Icft crankcase half Refer to Fig ure 91 and Figure 92 Make sure they are correctly seated 17 The crankcase assemblies are now ready to be joined l8 Make sure both crankcase scaling surf...

Page 167: ...set perform the fo l lowing a Install the threaded stud Figure 94 onto the crankshaft Screw it on until it stops and tighten it securely Do 110t overtighten b Position the right cra nkcase half onto t...

Page 168: ...kcase half 2 1 If removed install the oil coolant pump shaft mechan ical seal as previously described in this chapter 22 Install the camshaft drive gear as described in Chapter Four 23 Install all ext...

Page 169: ...ar or damage Repair the threads if necessary 8 Inspect the balancer gear Figure 1 7 for worn chipped Of missing teeth Ifany L eeth arc damaged also check the teeth on the balancer gear The gear is pre...

Page 170: ...164 CHAPTER FIVE d I I Connecting rod side play r I i I tJ Connecting ro radial play...

Page 171: ...r races of the bearings for each specific shaft assembly Crankshaft end pia I Make certain the crankshaft bearings A Figure 111 arc fully seated in both cra nkcase halves 2 Measure the thickness of th...

Page 172: ...ing Figu re 118 Note thc dimension and subtract the thickness of the straightedge in Step 2 Record this measurement 7 The specified balancer shaft end play is listed in Table 2 Use the following equat...

Page 173: ...pump shaft bearing Figure 120 Note the di mension and subtract the thickness of the straightedge in Step 2 Record this measurement 5 Using a dial vernier caliper or depth gauge care fully measure the...

Page 174: ...nner and outer rotors and dowel pin A Figure 128 from oil pump body B Figure 128 10 Inspect all components as described in the fol lowin g procedure CHAPTER FIVE Inspection Refer to the service limit...

Page 175: ...im 2 Drive gear 3 Drive shaft 4 Dowel pin 5 Washer 6 Screw 7 Intake screen 8 Bod y 9 Outer rotor scavenge 10 Inner rotor scavenge 11 Middle cover 12 Outer rotor feed 13 Innerrotor feed 14 Dowel pin 15...

Page 176: ...170 11 CHAPTER FIVE...

Page 177: ...Insert thc drive shaft into all three parts and rotate it and check for smooth operation 10 Inspect the feed set and the scavenge set of ro lars 8 Figure 137 for abrasion wear cracks or damage II Ins...

Page 178: ...specification listed in Table 1 9 Install the pump intake screen Figure 143 aud screws Tighten the screws securely NOTE Do not use any gasket sealant when installing the pump onto the crank case 10 Pr...

Page 179: ...igure 146 and remove the one way check valve and spring Fig ure 147 3 Clean the plunger spring and plug in solvent and thoroughl y dry Figure 148 4 Inspect the plunger for wear or damage and re place...

Page 180: ...essure blind plug 9 15 80 132 Oil pump Mounllng bolts 7 9 62 80 Cover screw 3 26 One way valve plug 19 26 14 19 Recoil starter housing bolts 7 9 62 80 Starter motor mounting bolts 7 9 62 80 Stator pla...

Page 181: ...the air intake At the primary throt tie opening idle a small amount of fuel is si phonedthrough the pilotjet bythe incoming air As the throttle is opened further the airstream begins to siphon fuel t...

Page 182: ...all hoses prior to disconnecting them from the carburetor 8 Disconnect the fuel supply hose Figure 3 from the carburetor Plug the end of the fuel supply hose 9 Loosen the front clamp Figure 4 slide th...

Page 183: ...the throttle case fitting B Figure 7 and attach the cable end to the lever Figure 10 b Tighten the thrott le cable fitting securely c Make sure the O r ing seal is in place on the throttle case prior...

Page 184: ...18 Seal 19 Seal 20 E rlng 21 Cap 22 Float pivot pin 23 O ri ng 24 Needle valve seal 25 Needle valve 26 Pilot iet 27 O ring 28 Washer 29 Spring 30 Pilot screw 31 Spring 32 Spring seat 33 Idle adjust s...

Page 185: ...loat bowl and O ring gasket Fignre 16 6 Carefully tap out the float assembly pivot pin A Figure 17 7 Pull straight up and remove the float assembly B Figu re 17 Do not lose the needle valve at tached...

Page 186: ...escribed under Cleaning and Inspection in this chapter 1 If removed install the throttle adjust screw spring scat and spring B Figure 27 and tighten se curely 14 Tum the carburetor on its side and rem...

Page 187: ...and into the post Push it in until it bottoms c After installation check that the needle jet flat is aligned with the Oat in the carburetor body Figure 29 4 Install the air jet Figure 23 and tighten s...

Page 188: ...14 To assemble the throttle valve diaphragm as sembly perform the following a Install the E c1ip A Figure 34 onto the jet needle in the correct location Refer to Table I for standard Esclip location b...

Page 189: ...sed cleaning solution Then clean in hot soap and water and rinse with hot water Thor oughly dry with low pressure compressed air CAUTION Ifcompressed air is not available al low he paris to air dry Dr...

Page 190: ...cuum slide or throttle valve and or jet block assembly 7 Inspect the jet needle tapered end for steps un even wearor other damage Replace ifdamaged 8 Cheek the inlet va lve needle sea t O ring seal A...

Page 191: ...Figure 48 and Figure 49 Clean out irthey arc plugged in any way then apply low pressure compressed air to all openings 16 Check the cover for cracks or damage replace if necessary 17 Make sure the thr...

Page 192: ...e correct distance is listed in Table 1 4 If the float setting is incorrect adjustas follows a Carefully bend the tang in the center of the float arm Figure 55 with a small screw driver to adjust the...

Page 193: ...ing will enrichen the mixture during mid throttl e opening while lowering the needle raising the E ring will lean the mixture 9 Install the jet needle vacuum slide and dia phragm as described in this...

Page 194: ...raps securing the cable to the frame 7 Mark the original path ofthe cab le by attaching a piece of string to the cable before withdrawing it 8 Make a note of the cable routing path through the frame t...

Page 195: ...p cover from the instrument panel cover b Remove the two screws securing the instru men panel cover and remove the cover c Unscrew the nut securing the toggle control knob to the instrument panel cove...

Page 196: ...5 Elbow 6 Fuel tank 7 Bolt 8 lockwasher 9 Washer 10 Mounting bracket 11 Collar 12 Fuel fitting 13 Main fuel line 14 Reserve fuel line 15 Clamp 16 3 way valve 17 Nut 18 Knob 19 Washer 20 Screw lot ligh...

Page 197: ...from the frame re ceptacles 12 Pull the fuel tank straight up and remove the tank along with both fuel hoses attached to the bottom of the tank Remove the fuel tank from the frame 13 Inspec t the tan...

Page 198: ...r inlet duct from the foam pad at the rear of the fuel tank 58 On 1999 and later models perform the follow mg a Remove the boll and wash er Figure 73 on each side securing the air box to the frame CHA...

Page 199: ...filter 3 Clamp 4 Retainer 5 Silencer boot 6 Air box 7 Wing nut 8 Cover 9 Gasket 10 Screw 11 Washer 12 Special nut 3 Hose clamp 1 14 Hose 15 Drain tube 16 Cap 17 Retainer plate 18 Nut tor Inlet tube 19...

Page 200: ...ollar 5 Screw 6 Inlet duct 7 Gasket 8 Cover 9 Gasket 10 Bo l 11 Washer 12 Air bo x 13 Clip 14 Insulation 15 Clamp 16 Drain tube 17 Cap 18 Hose 19 Breather filter 20 E 21 nqtne breather hose Gasket Car...

Page 201: ...fUEL SYSTEM 195...

Page 202: ...a mp th en dis connect the impulse hose A Figure 79 from th e pump 5 Working on the ba ck side of the fuel pump remove the two nuts from the mounting screws securing the fuel pump to the frame rai l 6...

Page 203: ...mpressed air 5 Inspect the inlet and outlet check valves for cracks warpage or damage 6 Check the diaphragms for cracks holes or swelling 7 Check the sealing surfaces of the pump body and both covers...

Page 204: ...acity are in Table 1 at the end ofthe chapter POLARIS VARIABLE TRANSMISSION PVT Am COOLIN G SYSTE l The Polaris Variable Transmission PVT assem bly is air cooled The air cooling system uses a cen trif...

Page 205: ...e sys tem to dry be fore proceeding Clutch O uter and InnerCover Dueling An obstruction in the dueling missing parts or leaking connections can increase the operating tem perature and shorten the life...

Page 206: ...rioration replace if necessary 10 Install the outcr cover onto the inner cover Make sure it is seated correctly around the entire perimeter with no gaps I I Install the single rear bolt and was her Fi...

Page 207: ...igure 13 securing the front seal and retainer to the crankcase 6 Pull the cover straightoutfrom the engine being careful not to damage the rubber seal Remove the clutch inner cover 7 Inspect the front...

Page 208: ...Chapter Five A mixture orethylene glycol antifreeze and dis tilled watercirculated by the water pump maintains engine temperature The coolant flows within the coolingpassages inside the cylinderblock...

Page 209: ...ystem keep the system filled with the correct mixture of ethylene glyco l antifreeze formulated for use in aluminum engines and distilled or purified water Maintain the coolant at the proper level as...

Page 210: ...ose that is to be replaced Slide the clamps from the component li t tings C HAPT ER SEVEN CAUTION Do not twist 10 0 liard or the f ittings may be damaged 4 Twist the hose to release it from the fitt i...

Page 211: ...eeding air from thc sys tem To pressure check the cooling system refer to Coo ani Inspection in Chapter Three RADIATOR RemO 3Ulnstallation 1996 1999 Mod els Refer to Figure 23 I Remove the fronl fende...

Page 212: ...ect the electrical connector from the temperature sensor A Figure 28 aod coo ling fan B Figure 28 at the top the radiator NOTE Even though the coo ling system has been drained there willsome residual...

Page 213: ...ou nting bracket 7 Screw 8 Upper hose 9 Screw 10 Fan assembly 11 Nut self locklng 12 Rubber mount 13 Spacer 14 Special nut 15 Fan shroud 16 Washer 17 Radiator 18 Cover 19 Fill cap 20 Gasket 21 Cap plu...

Page 214: ...APTER SEVEN I If compressed air is avai lable use short spurts of airdirected 10 the backside of the radiatorcoreand blow out dirt and bugs 2 Flush olTthe exterior of the radiator with a gar den hose...

Page 215: ...emb ly from the radi atorshroud 5 Install by reversing these removal steps COOLANT PUM P The engine must be removed from the frame and the crankcase must be separated to service thecool ant pump shan...

Page 216: ...pect the impeller Figure 41 for damage replace if I1CCCSS lIY 14 Clean all old gasket material from the back of the coolant pump cover Figure 42 and the crank case mating surface 15 Install the sealin...

Page 217: ...er Some residual cool ant may drain out 3 Loosen the clamp on the coolant hose A Figure 44 detach the hose from the thermostat fitting NOTE Thejh l lJI iJlg photographs areSl lO U 1l with the engine r...

Page 218: ...ll and bleed the cooling system as described under Coolant Change in ChapterThree TEMPERATURE SENSORS The liquid cooling system is equipped with two temperature sensors The sensor located on the en gi...

Page 219: ...nkshaftto the transmission by the Polaris Variable Trausmis sian PVT The drive unit automatically changes the drive ratio to permit the machine to move from idleto maximum speed Major components inclu...

Page 220: ...stem EBS was incorpo rated into the clutch drive unit on all models pro duced since 1999 This system has a unique feature that allows engine braking to occur when the vehi cle is coasting or going dov...

Page 221: ...ases centrifuga l force causes the weights of the drive pulley to swing fur ther out and forc e the sliding half of the pull ey closer to the fixed half As the groove of the drive pulley becomes narro...

Page 222: ...re 6 for 1999 on models equipped w ith EBS The pu lley sheaves arc made of mild stee l The belt surfaces arc machined to a smooth ta pered sur face The tapered surfaces of the pulley halves matc h the...

Page 223: ...ing 6 Bushing 7 Sliding sheave a Bushing 9 Spacers 10 Fixed sheave DRIVEN PULLEY 1999 0N MODELS WITH EBS 1 Bolt 2 Washer 3 Domed washer 4 Clrclip 5 Bushing 6 Washer 7 Fixedsheave 8 Bearing 9 Movable s...

Page 224: ...from the drive pulle y to the driven pulley The belt provides a vital link in the opera tion and performance of the ATY To ensure top performance the drive pulley drive belt and driven pulley must be...

Page 225: ...re removal Figure 11 b If installing a new belt install it so the belt identification marks Figure 8 can be read while standing on the left side ofthe machine Inspection Inspect the drive belt weekly...

Page 226: ...d Check the drive belt alignment as described in this chapter 2 Position a straight edge across the top of the drive bell as shown in Figure Ill 3 Compress the drive belt mid way with a linger to remo...

Page 227: ...hift ratio will be too short If the centers ofthe pulleys A Figure 20 arc too far apart or the belt is too short the drive belt will be pulled down too deeply in the driven pulley groo ve too soo n Th...

Page 228: ...222 r Engine PULLEY ALIGNMENT TransmIssion A PULLEY OFFSET B CHAI TER EIGHT Engine Transmission J 4...

Page 229: ...l the adjust ment by adding 0 removing washers between the frame and the f ront lower It engine mount Add a washer to increase clearance at A Figure 2 or A Figure 22 Follow the normal adjustment proce...

Page 230: ...e pulleys arc properly aligned remove the pulleys and reinstall the innercoveras described in ChapterSeven 7 Install the drive and driven pulleys as described in this chapter 8 Insta ll the drive belt...

Page 231: ...fore begin ning any disassembly to determine if the com po nents are in acceptable condition Install a new complete drive clutch asse mbly Figure 35 and Figure 36 if any individual component is dam ag...

Page 232: ...2 Thrust washers 13 Rolle r 14 Nul 15 Pivot bolts 16 Weig hts 17 Bushing 18 Cover bushing 7 4 DRIVE PULLEY 11999 0N MODELS WITH EBS 1 Screw 2 Washer 3 Cover 4 Sprin g 5 Spider 6 Button 7 Th rust washe...

Page 233: ...ion the fixed sheave over the clutch holder and secure the sheave assembly with the holding tabs Figure 42 Tighten the tab bolts securely c On 1999 on models unscrew Figure 43 and remove the spacer sl...

Page 234: ...the spider B Figure 45 counter clockwise with the VST spider removal tool A Figure 45 r Remove the spider B Figure 44 g On 1996 1998 models remove the spacer washers f igure 47 11 e same number and t...

Page 235: ...e spider Figure 53 with a VST Roller Pin special tool part No 2870910 e Remove the two thrust washers Figure 54 and the roller Figure 55 d Store the roller and bushing assembly as a set until inspecti...

Page 236: ...sheave drive belt surfaces A Figure 59 for rubber or corrosion buildup For properoperation the surfaces mustbe clean Remove debris with fine grade steel wool Clean witha piece of lint free cloth 5 Ch...

Page 237: ...r caliper Figure 63 Replace the spring if its free length is less than the free Icngth limit listed in Table 3 Replace thc spring with the same color code and wire diameter 8 Inspect the cover plate b...

Page 238: ...r proper opera tion Be ore changing the weights ill the drive pulley consult with a Po laris dealership I t Install new weights as a set ifany are damaged Weights are marked to indicate their orig ina...

Page 239: ...B Figure 57 through the weight b Apply ThreeBond TB 1342 Loetite No 242 or an equivalent to the threads of new locknuts and install the locknuts A Figu re 57 Tighten the locknut until it bottoms again...

Page 240: ...ding fixture is secure b Position the fixed sheave A Figure 75 over the clutch holder and secure the sheave as sembly with the holding tabs B Figure 75 Tighten the tab bolts securely c Install the VST...

Page 241: ...ong the shaft If binding is noted dur ing plate movement the fixed sheave shall is out of round Repair the shaft with a fine ti le unt il the plate moves freely Remove the cover plate 10 Install the s...

Page 242: ...onto the crankshaft Push it on until it bottoms 3 Install the bushing thick washer and lockwasher onto the bolt then install the bolt Figure 84 and hand tighten 4 Secure the drive pulley as follows a...

Page 243: ...3 Install the VST Driven Clutch Puller pan No 2870913 A Figure 89 onto the driven pulley Tighten the pulley and loosen the pulley from the transmission input shaft If necessary lap on the end of the p...

Page 244: ...th alit the lise of the specified VST spe cial tools may cause personal injury If the necessary tools are not avail able have the service performed by a Polaris dealership or repair facility with the...

Page 245: ...2 Install the same number of spacer washers that were removed onto the shaft The spacer washers are used to adj ust belt deflection and several may be installed but there must always be at least one...

Page 246: ...r to Fignre 99 The VST Clutch Compression Tool A Figure 100 part No 8700220 is required to disassemble the driven pulley WARNING The driven pulley is under spring pressure Attempting 10 disassemble or...

Page 247: ...Y 11999 0N WITH EBSI 5 Push down on the VST special tool and unlock the tool handle from the chain restraint Open the spec ial tool 6 Remove the bushing and washer Figure 103 7 Turn the driven pulley...

Page 248: ...m the chain restraint Slowly open the special tool I I Remove the helix A Figure 106 and spring B Figure 106 12 Remove the washer Figure 107 from the shaft 13 Remove the movab le sheave Figu re 108 an...

Page 249: ...sheave to hold all parts in place 5 Install the circlip Figure 113 into the shaft groove Make surethe circlip is correctly seated in the shaft groove Figure 114 6 Tum the fixed sheave over and instal...

Page 250: ...ure 121 12 Push down on the VST special tool and unlock the tool handle from the chain restraint Slow ly open the special tool 13 Make sure the circlip is correctly seated in the shaft groove Figure 1...

Page 251: ...alignment of the ends ofthe spring as shown in Fig ure 123 The ends of the spring arc aligned when new If the ends are no longer aligned or the spring has sagged replace the spring 4B 0 0 1999 00 mode...

Page 252: ...scratches 9 Inspect the shaft Figure 130 for wear or dam age Check the external splines A Figure 131 internal splines Figure 132 and circlip grooves B Figure 131 for wear Repa ir or replace the shaft...

Page 253: ...not covered in this chapter Table 1 DRIVE BELT AND PULLEY SPECIFICATIONS Item mm in Belt deflection non EBS models 29 32 1 14 1 26 Belt width New 29 8 30 2 1 174 1 188 Wear limit 28 6 1 125 Pulley ce...

Page 254: ...5 2 80 3 05 7041032 Plain 3 99 0 157 108 2 114 6 4 26 4 51 7041021 Blue green 4 05 0 159 61 0 67 6 2 40 2 66 7041157 Black 3 56 0 140 104 8 111 1 4 13 4 38 7041022 Table 4 SHIFT WEIGHTS AND DRIVEN PU...

Page 255: ...several brightly col ored shop cloths around each end to prevent running 1110 them Refer to Table I for tightening torque specifica tions and Table 2 for transmission specifications Transmission Serv...

Page 256: ...est and frame with the rear whee ls ofT the ground II Remove both rem wheels as described in Chap ter Thirteen 12 Remove the transmission output shaft brake caliper and brake disc Figure 3 as describe...

Page 257: ...s c Both drive axles d Stabilizer support 16 Remove the two lower bolts A figure 5 and two upper bolts Figure 6 securing the transmis sion upper front support bracket 13 Figure 5 Re move the bracket 1...

Page 258: ...ews and remove bothgearindicatorswitches A andB Figure 15 from the top of the transmission case 5 Set the transmission on wooden blocks with the left side facing up 6A On 1996 models remove the perime...

Page 259: ...1999 on 10 Rear switch th ree position 1999 on 11 Dipstick 12 O rings 13 Transm ission case 14 Nuts self lo ck ing 1996 models 15 Clrcllp 16 Shim 17 Bearing 18 Front output housing 19 Front output sha...

Page 260: ...ss pattern Continue to work around the cover until the tapping sound becomes dull The dull sound indicates that the cover is starting to sep arate Tryto inserta fingernail between the mating surfaces...

Page 261: ...II TRA SM ISSIox 255...

Page 262: ...on the two gears as sho wn ill Figure 28 13 Remove the chain tensioner assembly as fol 1 0 5 a Ca refully unhook the torsion spring from the rear dowel pin A Figure 29 and remove the torsion spring fr...

Page 263: ...mission ca e receptacle 16 Carefully pull the output gear and bearing as sembly 8 Figure 33 straight up and out of the transmission case 17 Disengage thechain fromthe center drive shaft C Figure 33 an...

Page 264: ...high low reverse shaft assembly the input shaft assembly the silent chain and high low gearshift fork from the transmission case as an assembly Figure 14 28 If necessary perform the following a Remov...

Page 265: ...screws and tighten the screws to the torque spec ification listed in Ta ble I 4 If the two shafts have been separated from each other correctly assemble the input shaft and high low reverse shaft and...

Page 266: ...hing it with the mating gear A Figure 52 on the high low reverse shaft Carefully tap on the shaft end B Figure 52 with a soil faced mallet to en sure the shaft is completely seated in the transmis sio...

Page 267: ...he shaft 21 Position the low gear with the shift dogs facing down Figure 58 and install the low gear past the input shaft bearing and onto the high low reverse shall 22 Center the low gcar A Figure 38...

Page 268: ...lip Figure 61 27 Apply ThreeUond No 1342 or equivalent threadlocking compound to the screw threadsprior to installation Install the oil deflector Fig ure 62 Do not overtighten the screws as the mounti...

Page 269: ...there is no binding 33 To install the dri ve chain tensioner perform the follow ing a On models so equipped install the two spac ers onto the transmission case and align the holeswith thetransmissionc...

Page 270: ...appl y sealant to the two raised posts Figure 74 for the two center bolts 37 If removed install thc three locating dowels F igures 75 77 onto the transmission case 38 Thoroughly lubricate the transmi...

Page 271: ...entire per imeter If necessary use a plast ic or son faced mal let and lap the cover into place in the areas of the shafi bearings Fi lI rc 79 CAU TION There lire two different size case bolls The tw...

Page 272: ...t have end play but should also not bind 42 Clean the sea ling surfaces uf the transmi s sion case and the inside surface of the bottom ac ces s plate with an aerosol parts cleaner 43 Apply an even co...

Page 273: ...nd of the shaft b Remove the eirclip and slide off the thrust washer e Slide off the high gear B needle bearing and washer d Slide off the high reverse engagement dog C c Remove the circlip and slide...

Page 274: ...33 teeth 19 Needle bearing 20 Low gea r engagement dog 21 High low reverse sha ft 22 Clrcllp 23 High reverse engagement dog 24 High gear 30 teeth 25 Oil deflector 26 Screw 27 Pin 28 Center dr ive sha...

Page 275: ...onto the need le bearing g Slide on the washer and install the new eire lip Make sure the circlip is correctly seated in the shaft groove h Ileat the hearing on a hot plate to aid in instal lation 1 I...

Page 276: ...cover gasket seal ing surfaces 3 Th oroughly che ck the gasket sealing surface of both parts Check for gouges or nicks that may lead to an oil leak 4 Inspect the case and cover Figure 96 for crack s a...

Page 277: ...sassembling them Place the assembled shaft into a large can or plastic bucket and thoroughly clean with a petro leum based solvent such as kerosene and a stiff brush Dry with compressed air or let it...

Page 278: ...agement dogs A Figure 107 If the edges of the engagement dogs are rounded or chipped replace the gear 8 Inspect the engagement dogs inner splines B Figure 107 for wear or damage If any of the splines...

Page 279: ...it as de scribed in ChapterOne d Inspect the gea r Figure Ill Any burrs pit ting or roughness 0 11 the teeth of a gear will cause wear on the mating gear 13 Inspect the output gea r as follows a Make...

Page 280: ...ssembly Remove the bell cra nk 8 Figure 119 5 Remove the circlip and washer securing the shift shaft into the transmission case 6 Withdraw the shill shall Figure 120 from the interior of the transmiss...

Page 281: ...manent marking pen to make an align ment mark between the front output housing and the transmission case Figu re 123 This will ensure correct alignment during installation 5 Loosen the output housing...

Page 282: ...ition 1999 00 10 Rear switch three position 1999 00 11 Dipstick 12 O rings 13 Transmission case 14 Nuts self locking 1996 models 15 Clrcll p 16 Shim 17 Bearing 18 Front outp ut housing 19 Front output...

Page 283: ...damage with duct or electrica l tape 13 If necessary use a brass hammer or press to withdraw the front output shaft bearing then the circlip shims ami oil seal out of the tran smission end of the fron...

Page 284: ...part No 2871701 A Figure 125 and screw the froot out put housing in until the O ring seal is 8 rnrn 0 31 in from the transmission housing then stop 9 Position the front output ring gear with the shou...

Page 285: ...is flush with the housing 22 Tighten the output housing pinch bolts Figure 131 sec urely Output Shaft End Pia Inspection and Adjustment This procedure requires the use of a dial indicator and stand I...

Page 286: ...emove the front output housing seal from the end of the housing 4 Install the VST special tool onto the output shaft splines as shown in A Fignre 132 Using the VST 2 118 inch wrench B rotate the outpu...

Page 287: ...e SHIFT SELECTOR LINKAGE Adjust the shift linkage as the first step to correct transmi ssion or shifting problems Shit linkage adjustm ent is necessary when the follo wing symptoms are evident 1 Whene...

Page 288: ...onbell crank on topoftile trans mission A Figure 140 and on the shift arm pivot plate B Figure 140 6 Place the gear selector in the NEUTRAL posi tion Makesurethe transmission bell cranks arcen gaged i...

Page 289: ...On 1996 1998 models perform the followi ng a Remo ve any cable ties securing the w iring _ harness 10 the frame b Disconnect the electrical wires from the ter minal board located on the frame panel ad...

Page 290: ...ecurely e Install the upper d amp and tighten it securely 58 On 2000 models perform the following a Apply a light coat of ThreeBond 12 15 gasket scaler to the body mating surface b Slide the rubber bo...

Page 291: ...Shift select rod 10 Bearing cup 11 Interlock pin 12 Interlock butterfly 13 Body 14 Spring 15 Stop pin 16 Detent spring 17 Detent pin 18 Pad models so equipped 19 Switch 1996 1998 20 High reverse range...

Page 292: ...hift selector body in a vise with soft jaws Locate the body so it is level CHAPTER NINE CAUTION Do nut add more oil thanspecified IS this could cause the gearshif selector to hvdrotock while sh f iiug...

Page 293: ...in the body 287 12 Withdraw both selector slides from the body 13 Inspect all parts as described in this chapter Assembly Refer to Figure 149 I Coat each selector slide O ring with clean en gine oil...

Page 294: ...low range 20 Cap 21 Torx screw 22 Knob 23 Shift select rod 17 13 23 17 1 3 IO 1O 121CI 1 5 16 i l 3 14 18 19 Inspection All Mo dels I Inspect the sciector slide a ring seals for dam age and hardness R...

Page 295: ...ion drain plug 19 14 Front output ring gear bolt 23 28 17 21 Pinion gear reta inIng plate screws 11 14 97 124 Bottom access plate screws 11 14 97 124 Bell cra nk nut 17 13 Shi ft rod to bell crank nu...

Page 296: ...nd is referred to as a lIill ard clutch Ta bles 1 3 provide tire and drive train specifica tions at the end of this chapter NOTE Tire size is l C important for proper operation all all models Ifthe ti...

Page 297: ...n 14 Retaining spring 15 Hubcap 16 Torx screws 3 Remove the front wheels as described in Chapter Twelve 4 Remove the front brake calipers as described in Chapter Fourtee n 5 Place a drain pan under th...

Page 298: ...clutch assembly f igure 8 NOTE Do 110 mix parts ofone Hillard clutch assembly with similar parts from an other clutch ussernbty 13 Remove the spacer Fig ure 9 14 Note the location of the armature pla...

Page 299: ...ched 0 0 far and must he re p aced I Thoroughl y clean the roller cage and roller as sembly Figure 12 in solvent and dry with low pressure compressed air 2 Inspect the inner splines Figure 13 for wear...

Page 300: ...g spring otTofthc special tool and onto the roller cage and into the groove holding the rollers in place Hillard C lutch Testing Prior to installing the clutch assembly in the front hub assemble and t...

Page 301: ...nce from the outer pole seal sleeve to the inner pole as shown in Figure t 16 Measure the pole gap in at least three location s and compare with the spec ification in Table 2 3 If the pole gap meas u...

Page 302: ...n and bend the ends over completely Figure 28 14 Inspect the hubcap O ring seals Figure 29 for nicks cuts anddeterioration Replace as necessary Apply a light coaling of grease to the O rings 15 Instal...

Page 303: ...ub 4 Apply a ligbt coat of oil to the seal seating sur face of the front bub and to the outer surface of the seal 5 Position the new seal with the spring loaded lip toward the bub 6 Carefully press th...

Page 304: ...Fifteen 3 Raise the front of the vehicle lip to gain working room under the frontstrut Secure thevehicle inthis position so it will not shill or fall while working on it 4 Remove the front caliper as...

Page 305: ...the end of the drive axle e Remove the small clamp C Figure 36 sc _ curing the rubberboot to the drive axle and slide the rubber boot off the drive axle Inspection Lubr tcatlon I Check the drive axle...

Page 306: ...may be necessary to tap on the end ofthe dri ve ax le with a plastic mallet to force the spindle past the eirelip f After the front spindle is installed pull back on it to make sure it is secured in...

Page 307: ...e dri ve shaft front universal joint and front drive unit shaft 5 Slide the dr ive shaft B Fi urc 44 toward the rear onto the transmission front output shaft until the front universal joint clears the...

Page 308: ...D INFLATION PRESSURE ICOLD Model Size kPa PSI Front wheels 25 x 8 x 12 34 5 5 Rear wheels 1996 25 x 12 xl0 34 5 5 1997 on 22 x l1 xl0 34 5 5 Tire pressure for original equipment tires Aftermarket tire...

Page 309: ...helps seal out mois ture and helps prevent corrosion of the electrical connector terminals Service information relating to the battery spark plug and ignition timing are covered in Chapter Three The...

Page 310: ...nder in place by removing the rear wheel h il l the working room is l el limited Remove whatever com ponent is most convenient l A Remove the rear fender as described in Chapter Fifteen 1B Remove the...

Page 311: ...996 1997 305 SPllrt plug Start Au sh ul button 0 swtlc h Key awheh Diagram Key Con c lon fGround FIIIITle ground Stator AUL PO plug ColOI Code 8 Blac k W Wl tlbt R G G_ t y 9IFl BilcklRecl W R WhllelR...

Page 312: ...AUli hut button off witch Key swltch Balterv DIagram Key Conneclon Ground f_ground t Cofloec tlon Au powM plug Colo r Cod e B Black W While R Rod G G_ L Blue Y VIflIow Sr Brown BIR BlaC klfMd W R WhlM...

Page 313: ...Key switch Diagram Key Con FrameOlOUnd No eon tlon R br ellk lll Voltage t ura tor Battery Colo r Code B Blec k White G nree n t Illue y Y ellow B B BlnclllR ed Whl1l1JRed Whlt l Ulue R llBleck Redl W...

Page 314: ...system overcomes all electrical system loads andbegins to charge the battery I Place the vehicle on level ground and set the parking brake 2 Test the bauery specific gravity as described un der Balle...

Page 315: ...from the alternator to the location where it connects to the voltage regu lator 4 Disconnect the two individual yellow and the yellow red electrical connectors from the voltage regulat or Figure 7 5 C...

Page 316: ...rectifier unit 5 Remove the three mounting screws and remove the voltage regulator rectifier unit 8 Figure 8 from the radiator upper shield Do not lose the heat sink located between the unit and the s...

Page 317: ...iagra m Key t _ _ ConllKtono around Frl1T 8 ground t Connec tion No connection SI B relay R Rfj 2 0 A R circuli breaker fj lO A R circuli C R breake R I Aux powe r Sf plug Color Code W While R Rod G G...

Page 318: ...switch Key switch Diagr am Key Connec tor f Ground F gr OVl ld eon_oan t No connecllon 3J tort relay B A Slator I l Battery AUll power plug CoI04 Code W White A G G_ L Blue Y Yellow at Brown SIR Bllle...

Page 319: ...nneetorl Ground rr gro und e Io n No conniKtlon _ gR St e relay R I R r _ r m I I I I VoRage regu lator Ballery Color Code w _ R G Green l Btue Y Yellow B Brown BffI BtecklReod WIR WhllB Alld WIL Whl...

Page 320: ...de cover as described in Chap ter Fifteen 2 Disconnect the spark plug wire and remove the spark plug Figure 13 as described in Chapter Three NOTE Make sure to use a A7lOWII good spark plug for this le...

Page 321: ...or starter gears solenoid and the handlebar mounted starter button An electrical diagram of the starting system is shown in Figure 16 and Figure 17 for 1996 2000 models Refer to the wiring diagrams at...

Page 322: ...iagr am Key Co rmectors Ground 8JR Bl8ekIRIId W J l WhllelRed W l WhlllllBl RIW RedlWlIlte VIR Vellowm ct Key swllch 20A circuit breaker Aux shul off switch lOA circuit breaker Aux power plug SIBrt 00...

Page 323: ...t _ _ C c1On f Ground fTWM 9round Colo r Code 0 Bisek W Whit e R Rod G tj L Blue 6 Vellow I I 0 0 Start1M 0 BIKlllRed mot w WhlllllRad Wn WhileIBluo R S Rlldfllinck Bllnory s ta rter reilly RlldlWhlte...

Page 324: ...OTOR 5 6 7 6 8 11 11 15 11 9 10 llA 8 I QJ liH jjR 1 Nuts 2 Insulated brush assembly 3 OMring 4 Rear cover 5 Washer 6 Shims 7 Armature 8 Boll 9 Long bolls 10 Special washer 11 O ring 12 Front cover 13...

Page 325: ...long throughbolts Figure 21 special washersand O rings NOTE n Step 3 and Step 4 record the thick ness and numberofshims Figure 22 installed on each end of the shaft as they are removed Be slIre 1 0 in...

Page 326: ...rornthe housing Figure 29 8 Clean all grease dirt and carbon from the arma ture case and end covers CAUTION Do not immerse any ofthe wire wind ings ill solvent because most solvents will damage the in...

Page 327: ...s dealership or electrica l repair shop 6 Usc an ohmmeter to perform the following a Check for continuity betw een the commuta tor bars Figure 34 there should be continu ity between pairs of bars b Ch...

Page 328: ...oval Tighten the nut securely 5 Install the shims Figure 42 onto the armature shaft NOTE Lubricate the end bushing with a sili cone non petroleum grease before installing the end covel 6 Compress the...

Page 329: ...that the O ring is 1101 twisted when installing the end COl e l 9 Install the front cover B Figure 46 onto the ar mature aligning the marks on the front cover with the housing Figure 47 NOTE Make sure...

Page 330: ...diseonnect the connector Figure 51 of the small white red wire attached to the starter solenoid 4 Switch the ohmmeter to R x I and connect one Icad to the small red wire attached to the solenoid and...

Page 331: ...electrical connector from the headlight bulb socket assembly Figure 56 e Disconnect the individual electrical connec tors from the DC outlet Figure 57 f Disconnect all electrical connectors from the...

Page 332: ...or ignition swi tch 30 Enrich ment choke knob 22 23 1 Indicators 2 Speedometer 3 Screw 4 Special nut 5 Headli ght upper pod 6 Wiring harness 7 Speedometer mount models so equipped 8 Wash er 9 Lockwas...

Page 333: ...8 d Con nect the individual electrical connectors onto the DC outlet Figure 57 e Move the upper pod partially down onto the lower pod and connect the electrical connec tor onto the headlight bulb sock...

Page 334: ...onnect the electrical connector from the headlight bulb socket assembly Figure 56 from the headlight case as previously described 2 Remove the G ring from the locking tab on each side 3 Lift up on the...

Page 335: ...it before installing 4 Install the screws securing the lens to the hous ing and tighten securely but do not overtighten the screw as the lens may crack 5 Make sure the rubber gasket seal is seated all...

Page 336: ...hten the nuts securely 6 Install the headlight upper pod Speed Sensor 1999 0 n Sportsman Models Remova IIInstalla lion I Remove the right side front wheel as described io Chapter Twelve 2 Remove the f...

Page 337: ...nector plug Operate the switch in eac h of its operating positions and compare the res ults with the sw itch operating diagram For example Figure 72 starter sw itch shows which terminals should have c...

Page 338: ...curing the instru ment panel cover and remove the cover 3B On Sportsman models remove the headlight upper pod as described unde r High Beam Headlight Sportsman Models Bulb Replacement in Chapter Eleve...

Page 339: ...pter 2 Remove the front fender A Figure 86 as de scribed in Chapter Fiflccn 3A On Xplorcr models perform the following a Remove the top cover from the instrument panel cover b Remove the 1 0 screws se...

Page 340: ...cement in this chapter 3 Unscrew the nut A Figure 88 securing the sw itch to the lower pod Remove the switch 8 Fig ure 88 through the backside ofthe headlight lower pod 4 Disconnect the key switch ele...

Page 341: ...ctrical connectors are secure WIRING J AGRUIS Wiring diagrams for all models are located at the end of this book Item Table 1 ELECTRICAL SYSTEM SPECIFICATIONS Specification Alternator output 1996 1997...

Page 342: ...1998 0n Taillight Brake light Indicator lights 1996 1997 on Table 2 REPLACEMENT BULBS Specification 12 volt 60 60 watt Halogen 12 volt 37 5 wall 2 12 va ll 35 watt 2 12 vall 27 watt 2 12 Vall 8 26 wa...

Page 343: ...num casting Two tic rods that are attached to the stee ring sha ft and front strut arms control the steering Tables 1 3 are located at the end of this chapter FRONT WHEEL Removal I nstnllatfun I Place...

Page 344: ...lled rotate it and apply the front brake several times to make sure that the wheel rotates freely and that the broke is operating correctly 12 Lowerthe front of thevehicle to ihc ground and re check t...

Page 345: ...r 4 Upper ball pivot 5 Nut 6 Low er ball pivot 7 Upper spring seat 8 Spring 9 Strut 10 Lower spring seat 11 Clamp 12 Wire retainer 13 Roller bearing 14 Outer race 15 Sleev e seal 16 Magnetic coli 17 G...

Page 346: ...l lower when the nut is remo ved 7 Remov e the nut Figure 6 and lower the front strut assembly out of tile frame 8 Remove the uppe r ball pivo t Figure 7 IJjf RNING Do not remOl e the spring without a...

Page 347: ...off the strut 14 Remove the lower spring seat Figure 13 from the strut 15 If the spring is going to be replaced slowly and _ carefully loosen and remove thespring compressor Figure 14 from the spring...

Page 348: ...t vel slowly to avoid damaging he strut support ISe Carefully spread the front strut joint with an aluminum or brass tool sufficiently to release the strut Withdraw the strut from the strut support 18...

Page 349: ...ntly forinstallation 6 Install the co mpressed spring over the strut and set it on the lower spring seat Figure 2 7 Install the upper spring scat 8 Figure II and lower ball pivot onto the spring 8 Ins...

Page 350: ...veh icle on leve l ground and set the parking brake Block the rear wheel so the vehicle will not roll in either direction 2 Raise the front ofthe vehicle up to gain working room under the support str...

Page 351: ...nspection I Clean the strut assembly in solvent and dry 2 Inspect the strut support for cracks or damag e Figure 27 3 Check the tic rod end mounting boss A Figure 28 and the frontbrake calipermounting...

Page 352: ...ut support upside down in a vise with softjaws NOTE It may he Ilecessmy to heat thefro nt strut to soften the threat locking cum pound Heat the area with an indus trial gra de heat gun s do 1 01 apply...

Page 353: ...the long bushing and flat bushing from each end of the contro l arm 2 Withdraw the shaft from the control arm 3 Clean par ts in solvent and dry them with com pressed air 4 Inspect the control arm for...

Page 354: ...qu ipped 8 Washer 9 Lockwasher 10 Self lock ing nut 11 Bolt 12 Handlebar 13 Upper holder 14 Lowe r holder 15 Pod mountin g bracket 16 Screw 17 Washer lB Headl ight 19 Cove r 20 High beam headlight 21...

Page 355: ...ect the problem immediately 5 lnstall the front drive axle as described in Chap ter Ten 6 Install the front strut as described in this chapter 7 Install the front wheel as described in this chap ter 8...

Page 356: ...e assembly on the front fender Do not allow the cable to be kinked crimped or dam aged 6A On Xplorer models perform the following a Remove the four bolts and self locking nuts securing the handlebar u...

Page 357: ...rcr models perform the followi ng a Install the instrument panel cover and two screws Tighten the screws securely 351 b Install the top cover onto the instrument panel cover lOB On Sportsma n models r...

Page 358: ...locks 3 Clamp 4 Nut 5 Frame 6 Bolt 7 Cotter pin 8 Washer 9 O r ing 10 Lower bus hi ng block 11 Spacer 12 Thrust bearing 13 Washer 14 Nut 15 Long bushing 16 Flat bushing 17 Grease fitting 18 Control A...

Page 359: ...ie rod up and olrthc steer ing ann portionofthe front strut Remove the washer Figure 47 located between the two parts f Secure the outer end of the tie rod to the frame witha bungee cord orpiece ofwir...

Page 360: ...nspection NOTE rhe1J cleaning the tie rods do not im merse the outboard end ball joint in any type ofso rent that could contami nate the grease and or damage the rubber boot I Clean the tie rod and dr...

Page 361: ...knuts untilthe toe out is adjusted as described in Front Wheel Toe out inChapterThree Installation ff 4RNING It is important to install the tie rods with the em sl ueing the correct direc tion so the...

Page 362: ...fteen 2 Remove the fuel tank as described in Chapter Six 3 Remove both front wheels as described in this chapter 4 Remove the inboard ends of both tie rods from the two plates on the base of the steer...

Page 363: ...ng shaft from the frame as de scribed in this chapter 2 Drill out the rivets attaching the bushing block to the frame and then remove the bushing block 3 Clean the frame bushing mount ing area thor ou...

Page 364: ...sing tire irons Fi gu re 59 9 Clean the rims and tire sealing surfaces 10 Inspect the tire scaling surface on both sides of the rim Figure 60 If the rim is bent it may leak air Repair or replace the r...

Page 365: ...d unseat the bead completely Lubri cate the bead and re infl ate the tire 23 Chec k for air leaks and install the valve cap Cold lleh Repair This is the preferred method to patch a tire The rubber plu...

Page 366: ...with talcum powder CHA PTER TWELVE Item Table 1 FRONT SUSPENSION SPECIFICATIONS Specification Independent MacPherson strut front suspension Turning radius unloaded Front strut travel 165 em 65 in 15 8...

Page 367: ...ON AND STEERING Table 3 TIRE INFLATION PRESSURE COLO 361 Model kPa PSI Front wheels 34 5 5 Rear whee ls 34 5 5 n re pressure for original equ ipment tires Aft er market tires may require different Inf...

Page 368: ...cure the bolt to the correct tighten jug torque specification WARNING The majority the procedures in this chapter spec j the removal ofthe rear rack and rear lender After the rear fender is removed th...

Page 369: ...d tighten the lug nuts in a crisscross pattern to the torque specification listed in Table 2 NOTe In Step 12 make sure both rear wheels are offthe groundprior to rotating the wheel 12 After the wheel...

Page 370: ...re 5 for oil leakage and make sure the damp er rod 8 Figure 5 is straight Also inspect the rod for rust or other dama ge 2 Inspect the upper Figu re 6 and lower A Fig ure 7 rubber pivot bushings for w...

Page 371: ...hicle sec urely with the rear wheels off the ground 4 Remove the rear whcclis as described in this chapter 5 Remove the hub CHp Figure 10 6 Remov e the colter pin Figure 1l and discard it A new cotter...

Page 372: ...ng 5 Bushing 6 Stabilizer linkage rod 7 Stabilizer support 8 Washer g Bushing 10 Mounting bracket 11 Bushing 12 Bushing 13 Uppe r control arm 14 Frame mounting bracket 15 Grease lilting 16 Rear axle b...

Page 373: ...REAR SUSPEi SIOI 367...

Page 374: ...should be a tight fit with no rotat ional move ment If damage is minor clean it upwith a file If damage is severe replace the dam aged part s 4 Check the lug nut studs 8 Figure 18 for dam age Repluce...

Page 375: ...arm Apply a light coat ofgrease to the outer surfaces of the bushings 3 Install the rearaxle bearing carrier onto the rear axle and push it on until it stops 4 Install the rear axle bearing carrier o...

Page 376: ...x le bearing carrier as de scribed in this chapter 2 Remove the circiip B Figure 22 3 Tum the bearing carrier over and place it on wooden blocks 4 Using an app ropr iate size drift placed in the reo l...

Page 377: ...l joint to the internal threaded spacer located within the transmission output gear h Hold onto the rear axle slowly pull the rear axle out of the transmission while loosening the bolt c Remove the re...

Page 378: ...eplaced by a Polaris dealership c Inspect the outer splines on the universaljoint yoke for wear where it attaches to the trans mission output gear d Inspect the internal threa ded spacer for dam age r...

Page 379: ...xle and tighten the bolt to the torque specification listed in Table 2 9 Install the left side rear axle bearing carrier and rear hub as described in this chapter 10 Rotate the rear axles by hand to m...

Page 380: ...cklnq nut 5 Bushing 6 Stabilizer linkage rod 7 Stabilizer support 8 Wash er 9 Bu shin g 10 Mounting brac ket 11 Bu shing 12 Bushing 13 Upper control arm 14 Frame mounting bra cket 15 Grease fitting 16...

Page 381: ...per and Lower Control Arm Inspection in this chapter 9 Install by reversing these removal steps while noting the following a Grease the upper control ann bushings prior to installation Make sure the b...

Page 382: ...ounting bracket on the frame 9 Remove the lower control arm 8 Figure 46 from the frame lO Inspect the lower control arm as described un der Upper and Lower Control Arm Inspection in this chapter I I I...

Page 383: ...ar or damage Check the mounting holes forcracks or elongation 4 Thoroughly clean the pivot holts pivot bushings and shaft in solvent and dry with compressed air 5 Insert thc pivot bolt or shaft A Figu...

Page 384: ...and bolt onto the rod 6 Remove the boltandself lockingnut B Fi ure 58 securing the stabilizer arm bracket to the stabi lizer support 7 Remove the stabilizer arm bracket C Figure 58 from the stabilizer...

Page 385: ...erioration Replace all four bushings as a set even ifone or two are damaged STAB ILIZER SUPPORT Remova1 1nstullation Re fer 10 Figurc 40 I Remove the rear fender as described in Chapter Fifteen 2 Remo...

Page 386: ...EE NOTE II may be neceSJlII v10 slightly ower the rear ofthe transmission 0 ease stabilizer support remo val Ifso raise the transmission hack lip 10 the nor mal position after the support is re moved...

Page 387: ...fication Independent progressive rate rear suspension with anti roil bar and dual shock absorbers Rear suspension travel 24 em 9 5 In Ta ble 2 REAR SUSPENSION TORQUE SPECIFICATIONS Item Nom In lb ft l...

Page 388: ...shaft brake The rear master cylinder also controls the dual hydraulic outp ut shall brake The output shaft brake caliper can be controlled by ei ther or both master cylinders Brake Service The disc b...

Page 389: ...raulic system has been ope ned not in cluding the reservoir cover the system must be bled to remove air from the system Refer to Bleeding the System in this chapter WARNING Whenever working on the bra...

Page 390: ...y over the piston Figure 5 Tighten f4 the C c1amp and push the mounting bracket and the J brake pads in toward the piston and push the piston back into the caliper cylinder Co nstantly check the reser...

Page 391: ...caliper Figure 8 Replace the brake pads if the thickness of either pad is worn to the service limit in Table I 11 Inspect the brake disc for nicks corrosion and radial groove damage If damaged remove...

Page 392: ...brakef luid as it can calise brake component damage leading fa brake sys temfailure 19 Refill the master cylinder reservoir to maintain the eorreet lluid level as indicated on the side of the reservo...

Page 393: ...necess01 for piston removal during caliper disas sembly a Remove the brake pads as described in this chapter b Reinstall the caliper assembly and tighten the caliper mounting bolts securely CAUTION D...

Page 394: ...ure 18 securely e Bleed Ihe brake as described under Bleeding the System in this chapter WARNING Make sure the brakes are operating properly bef ore riding the vehicle Disassembly Refer to Figure l I...

Page 395: ...ace the caliper assembly 4 Inspect the brake hose inlet fining threads B Figure 20 in the backside of the caliper body If worn or damaged clean out with a thread tap or rc place the caliper assembly 5...

Page 396: ...the disc Assembly NOTE Use OIl V nell DOT3 brakefluid when brake fluid is calledfor ill the fo llow lug procedure I Install the bleed valve into the back side of the caliper and tighten sec urely 2 So...

Page 397: ...e right side foot well 4 Discon nect the foot brake lever linkage rod from the caliper 5 Remove the t I O bolts lockwashers and washers securi ng the brake caliper to the transmi ssion and mo ve the c...

Page 398: ...Caliper brake arm 4 Seal 5 Stationary ramp 6 Movable ramp 7 Washers 8 Nut left hand threads 9 Gasket 10 Apply pin 11 Spring 12 O ring 13 Lockwasher 14 Washer 15 Bleed screw 16 Body 17 Plate 18 Brake p...

Page 399: ...fluid leakage overhaul the brake caliper as described in this chapter NOTE When purchasing ne v pads check with he dealership to make sure the friction compound 0 the flew pad is compatible with the...

Page 400: ...in this chapter NOTE The following instructions apply to original equipment o pe pads only If using aftermarket brake pads fo llow the manufacturer s break in instruc tions 24 Bed the pads in gradual...

Page 401: ...better illustrate the step It is no Ilecessmy to remo e the caliper brake arm 4 Remove the two screws Figure 32 then re move the stationary ramp assembly Remove the gasket from the caliper body and di...

Page 402: ...ven wear The pins must be clean and in good condition for proper brake operation 8 Inspect the caliper body for damage replace the cal iper body if necessary 9 Inspect the caliper piston bore for crac...

Page 403: ...install the piston into the cylinder bore 9 Apply high temperature grease to the brake ap ply pin and install the spring and pin into the body Figure 33 10 Instal a new gasket on the body I I Refer t...

Page 404: ...reely If they do not remove and service the caliper as described in this chapter II Inspect the brake pads Figure 39 for uneven wear damage orgrease contamination Replace the pads as a set if necessar...

Page 405: ...eservoir if neces sary to maintain the correct fluid level as indicated on the side of the reservoir Install the diaphragm and coverand tighten the screws securely 20 With the wheels still off the gro...

Page 406: ...the brake pads as described in this chapter CAUTION Do not allow the pistons to travel Dill far enough 0 come ill contact with the brake disc Ifthis happens the pistons may scratch or gouge the disc d...

Page 407: ...piston seals dust seals and piston are available I Remove the caliper as described in this chapter 2 Remove the Allen bolt Figure 46 securing the caliperhalves together 3 Carefully separate the calipe...

Page 408: ...51 in each caliper body for damage If il is dama ged or corroded replace the caliper assemb ly 4 Inspect the brake hose inlet Ihreaded holes and fittings Figure 52 in the caliper body If worn or damag...

Page 409: ...ess is with specification c1can off the pad surface with an aerosol brake cleaner 10 remo ve any surface contamination NOTE When the brake system is operating correctly the inboard and outboard brake...

Page 410: ...alves together Fig ure 60 and make sure the locating pin and both small O ring seals arcstill located correctly 10 Install the Allen bolt Figure 46 securing the caliper halves together Finger tighten...

Page 411: ...d seal it 12 Install by reversing these removal steps while noting the following a Move the master cylinder to a position where the brake lever suits the desired riding posi tion then tighten the clam...

Page 412: ...t 1 2 5 j r 26 6 r I 27 I i 28 Y 1 Screw 2 Cover 3 Diaphragm 4 BaHle washer 5 Baffle 6 Pivot bolt 7 Sight glass 8 Seal 9 Body 10 Clamp 11 Screw 12 Washer 13 Sprln9 14 Cup 15 Piston 16 O ring 17 Dust s...

Page 413: ...ER 11999 0NI 16 15 12 1 Screw 2 Top cover 3 Diaphragm 4 Reservoir 5 Reservoir seal 6 Screw 7 Parking brake lever 8 Nylock nut 9 Spring 10 Brake lever 11 Pivot pin 12 Piston spring assembly 13 Pivot bo...

Page 414: ...of wear and dam age 3 If the reservoir was removed make sure the compensating and supply ports arc clea r 4 Make sure the fluid passage in the bottom of the master cylinder reservoi r is clear nspcct...

Page 415: ...eat as described in Chapter Fifteen 3 Remove the front and rear fenders as described in Chapter Fifteen 4 If not removed during rear fender removal re move the right side foot well 5 Cover the area un...

Page 416: ...Boll 2 Bracket 3 Plug 4 Reservoir 5 Nut 6 Hose cl amp 7 Reservoir hose 6 Master cylinder 9 Brake lin e 10 Plunger 11 Cotter pin 12 Clevis pivot pin 13 Clevis 14 Li nkage 15 Washer 16 Bushing 17 Lever...

Page 417: ...cle on level ground and bloek the wheels so the vehicle cannot roll in either direction 2 Remove the seat as deseribed in Chapter Fifteen 3 Remove the front and rear fenders as described in Chapter Fi...

Page 418: ...4 Install by reversing these removal steps while noting the following a Install the brake line to the master cylinder and tighten securely b Tighten the master cylinder mounting bolts securely e Refil...

Page 419: ...e fluid 8 Slide the rubber boot Figure 63 ofT the brake hose fitting 9 Remove the banjo bolt and scaling washers B Figu re 62 securing thc upper brake hose to the master cylinder Place the loose end o...

Page 420: ...Remove any tie wraps securing the brake hose s to the chassis 6 Note the routing ofthe brake hose s through the frame and suspension components The brake hose s must follow the exact same path when i...

Page 421: ...heend ofthe brakehosesovera container and let thebrake fluid drain out intothecontainer 5 Removeanytic wrapssecuringthe brake hose s to the chassis 6 Note the routing ofthe brake hose s through the fr...

Page 422: ...vis pin securing the linkage to the rear master cy linder clevis c Remove the 1 10 bolts and nuts securing the pivot mo unting plate to the frame and remove the assemb ly 4 To disassemble the pivot mo...

Page 423: ...ese removal steps while noting the following a Apply grease to all pivot points and sliding surfaces prior to installation b Install li eu cotter pins and bend the end s over completely FOOT BRAKE I99...

Page 424: ...t important but rad ial scratches deep enough to snag a fingernail reduce braki ng effectiveness and increase brake pad wear lfthcse grooves arc evident and the brake pads are wearing rapidly replace...

Page 425: ...ke cleaner Never usc petroleum based solvent that may leave an oil residue on the disc Do not touch the pad sur face of the disc after cleaning Removal Installation I To remove the front brake disc pe...

Page 426: ...ear fender and right side footwell as described in Chapter Fifteen 3 Remove thc dust cap s from the bleed valve on the caliper assembl ies Refer to Figure 91 for the front and Figure 92 for the rear 4...

Page 427: ...the brake hose hole in the master cylinder and fill the reservoir with DOT 3 brake fluid Do not remove the thumb d While holding a thumb over the hole pump the brake lever or pedal several times Then...

Page 428: ...er and chain guard as de scribed in Chapter Fifteen WARNING Bef ore riding the ATV make certain that tire brake is opera ting correctly C HA I TER FO URTEEN by operating the lever anil pedal sev eral...

Page 429: ...about one half turn Allow the lever or pedal to travel to its limit When this limit is reached tighten tbe bleed valve e At the output shaft caliper assembly open the bieed valve about one balft urn...

Page 430: ...25 362 25 3 1 0 9970 0 9985 0 9965 Brake disc thickness Front brake 3 810 4 166 3 556 0 150 0 164 0 140 Output s haft all models 4 496 4 750 4 242 0 177 0 187 0 167 Brake disc thickness variance 0 051...

Page 431: ...kets bolts nuts and was hers be reinstalled so they will not be misplaced SEAT Removal lnstallarion I Lift the scat latch at the rear of the scat Figure I pull the seat toward the rear and disengage t...

Page 432: ...J r Ii V J r OIN RAIL AND GRILLE FRONT RACK 1 I 1 Front rack rail Front rack Torx bo ll T 27 4 Reflex reflector 5 Boll 6 Boll nt 7 Rack mou headlight 8 Low beam 9 Screw 10 Side support 11 Nul 12 Grill...

Page 433: ...cle on level ground and set the parking brake 2 To remove the front rack perform the following a Remove the two screws Figure 5 on each side securing the front rack and front rack rail to thc rack mou...

Page 434: ...428 CHA PTER FIFTEEN 1 Fender cover 2 Front fender 3 Screw 4 Side panel 5 Boll 6 Nut 7 Footwell 8 Mud guard 9 Special nut...

Page 435: ...ring removal and installation 3 Grasp the rear portion ofthe side panel with both hand s 4 Pull the panel forward and straight out and dis engage the two rear lockin g tabs F igure 12 from the rear fe...

Page 436: ...g bracket Fig ure 17 8 Remove the upper inner bolt washer and nut Figure 18 securing the fender and mudguard to the footwell Repeat for the other side 9 Remove the two lower inner screws A Figure 19 s...

Page 437: ...umper 6 Install by reversing these removal steps Tighten the bolts securely RADIATOR GUARD Refer to Figure 23 l Park the vehicle on level ground and set the parking brake 2 On model s so equipped remo...

Page 438: ...CHAPTER FWrEEN 1 Bolt 2 Washer 3 Nul 4 Frame plug 5 Extension 6 Radiator guard 7 Grille 8 Radiator side shield 9 Special nut 10 Mounting plate 11 U bolt hitch models so equipped 12 Front bumper model...

Page 439: ...olt 14 Self locking nut 15 Rack mount 16 Washer 17 Spacer 18 Washer 19 Bolt REAR RACK Removal Installation Refer to Figure 28 I Park the vehicle on level ground and set the parking brake 433 2 Remove...

Page 440: ...434 CHAPTER FIFTEEN 1 Bolt 2 Washer 3 Seat retainer 4 Rear fender 5 Screw Mud guard Special nut 8 Footwell 9 Fram e support 1 part of frame O Bolt 11 Rubber gro 12 Selt lockln mmet 9 nut REAR FENDER...

Page 441: ...he mudguard to the footwcll 4 Repeat for the other side 5 In the area under the seat remove the four bolts and washers A Figure 34 securing the rear fender to the frame Do not remove the two bolts sec...

Page 442: ...en the screws securely b Install new self locking nuts ami tighten se curely REAR BUMP ER MODELS SO EQUIPPED Removal Installation I Park the vehicle 011 level ground and set the parking brake 2 Loosen...

Page 443: ...003 models including the Sportsman 400 If a specific procedure is not in cluded in this Supplement unless otherwise speci fied refer to the information in the previous chapters of this manual The head...

Page 444: ...ia grams at the end of this manu al for the specific mod el and year being worked on V Exciter Co il and Trigger Coil Test Refer to Table 3 for test specifications I Locale the electrical cables leadi...

Page 445: ...new pads if they are wo rn to the wear limit groove or to the dimen sion listed in Ta ble 4 There is also a new front maste r cylinde r The front brake calipers on all models arc the same Front Brake...

Page 446: ...E TOP END Refer to Table 5 ge nera l cngme specifica tions Th e Sportsman 400 model was introduced in 200 I Th is veh icle is basica lly the same as the larger 500 cc model with the major change take...

Page 447: ...engine mounting hardware Flgure t After the engine is removed from the frame in speer all ofthe rubber mounts for damage and or Removal I nstallation The flywheel and stator plate service procedures a...

Page 448: ...and frame 14 Place a clean lint free shop cloth or a plug into the intake manifold to keep out debris 15 Install by reversing these removal steps while noting the following a Insert the throttle cab l...

Page 449: ...17 Choke plunger guide 18 Collar 19 Washer 20 E cllp 21 Cap 22 Screw 23 Throttle plate 24 Air jet 25 Cover 26 O ring gasket 27 Throttle shaft 28 Spring seat 29 Spring 30 Lockwasher 31 Case 32 Collar 3...

Page 450: ...throttle valve diaphragm as sembly perform the following a Onto the jet needl e install the E elip b Install the spacer and the spring scat SUI I LEMENT e Install the jet need le assembly into the th...

Page 451: ...e plunger spring and guide holder for wear or dam age 16 Make sure all openings in the carburetor body arc clear Clean out if they are plugged in any way then apply low pressurecompressed air to all o...

Page 452: ...g the E ring will lean the mixture 9 Install the jet needle vacuum slide and dia phragm as described in this chapter Main let Replacem ent The size of the main jet affects the air fuel mix ture during...

Page 453: ...pari of the fixed sheave is not a separate component Follow the dis assembly and assembly procedures described in Chapter Eight and refer to Figure 7 while servicing the fixed sheave o DRIVEN PULLEY 2...

Page 454: ...e followin g The rear disc brake assembly is now located on the right side rear wheel hub CHAPTER ELEVEN ELECTRICAL SYSTEM LIGHTING SYSTEM High Beam Headlight 2003 Models Bulb replacement The removal...

Page 455: ...ition and connect the two multi pin electricalconnectors onto the speedometer 7 lnstall the three screws securing the headlight upper pod to the lower pod CHAPTER TWELVE FRONT SUSPENSION AND STEERING...

Page 456: ...450 9 STEERING SHAFT 12002 0N MODELS 6 4 f 8 o 10 6 iJ L ll 1 Locknut 2 Upper bushing blocks 3 Clamp 4 Bolt 5 Steering shaft 6 Bushing 7 Flange plate 8 Bearing 9 Frame 10 Cotter pin 11 Nul SUPPLE IENT...

Page 457: ...nt Lower Bearing Replacement All models arc equipped with the upper bushing blocks and the lower bearing The upper bushing is a split block and the lower bearin g is bolted to the frame I Remove the s...

Page 458: ...h conical washers Figure 18 from the axle NOTE II may be necessary to use a wheel puller to remove the rear hubfrom the end ofthe rear axle IO Remove the rear hub Figure 19 from the rear axle I I Remo...

Page 459: ...ing and to the rear axle shaft where the bearing rides 2 Make sure the inner bushings B Fi ure 21 are in place on the lower control arm Apply a light coat _ of grease to the outer surfaces of the bush...

Page 460: ...t and install the wa shers Figure 18 and the castellated ax le nut Figure 24 onto the rear axle I I On the right side install the rear brake caliper B Figure 16 as described in this suppleme nt 12 Hav...

Page 461: ...s replace both pads in the caliper at the same time Do 110 t disconnect the hydraulic brake hoses from the brake caliper for brake pad replace rnent disconnect the hoses only if the caliper as sembly...

Page 462: ...to it over flowing 9 The piston shou ld move freely If it does not reo move and service the caliper as described in this chapter 10 Remove both slide pin bolts Figure 31 loos ened in Step 6 II Remove...

Page 463: ...care ful not to damage the leading edge of the brake pads 2 1 Install both ca liper mo uoting bolts B Figure 29 and tighten to 25 Nvm 18 H lbs 22 Tighten the slide pin ho lts A Fig ure 29 to 41 48 Ns...

Page 464: ...issorjack Place the jack under the frame with a piece of wood between the jack and the frame 3 Place blockts under the frame to support the ve hicle securely with the rear wheels off the ground 4 Remo...

Page 465: ...leading edge of the brake pads c Install both caliper mounting bolts A Figure 39 and tighten to 25 Nsm I 8 ft Ibs d Install new sca ling washer on each side ofthe banjo bolt fittings and tighten tbe...

Page 466: ...3 brake fluid Wear eye pro tection and blow dry with compressed air directing the air flow and residual fluid away from you 2 Make sure the fluid passageways in the base of the piston bore arc clear...

Page 467: ...gether 8 Install the anvil bolts securing the caliper halves together and tighten securely 9 Install the bleed valves and tighten securely 10 Install the bracket the brake pads and the cali per as des...

Page 468: ...and bleed the brake as described in this chapter WARNING Do not ride the vehicle until the brakes are working properly Make sure that the brake lever travel is not excessive and that the lever does no...

Page 469: ...Screw 2 Sig ht glass 3 Cover 4 Diaphragm 5 Pin 6 Lever pivot pi n 7 Bolt 8 Clamp 9 Lever 10 E clip 11 Body 12 Outer dust see 13 Ptunqer 14 Spring 15 Seal 16 Piston and return spring assembly ttern Nos...

Page 470: ...2 If removed position the piston cups with the open end facing toward the inner spring end of the piston InstalI the cups onto the piston CAUTION When installing the piston assembly do not allow tile...

Page 471: ...frame bracket 12 Remove the master cy linder from the frame 13 If necessary remove the bolt 1I1d nut Figure 46 securing the reservoir to the frame Remove the reservoir and hose from the frame 14 Inst...

Page 472: ...se end of the brake hoses in a reclosablc plastic bag topreventthe entry offoreign matter and prevent any residual brake fluid from dripping out 9 Usc a flare filling wrench and loosen then dis connec...

Page 473: ...tion RSE 3 Model letters denote different colors and graphics Table 2 GENERAL DIMENSIONS Model 400cc Heig ht length Width Wheel base SOOce Height length Width Wheel base 2001 2001Models em in 116 8 46...

Page 474: ...li ng system Bore and stroke Sportsman 400 Sportsman 500 and SOD H D Displacement Sportsman 400 Sportsman 500 and 500 H O Compression ratio Sportsman 400 Sportsman 500 and 500 H O Four stroke SOHe sin...

Page 475: ...peed Specification BST40 Mikuni 152 5 KE 3 683 6MGH1 94 3 X 6 120 1 3 2 1 2 turns out 2 turns out 1 5 13 7 15 7 mm 0 539 0 618 In 1100 1300 rpm Table B REAR SUSPENSION AND BRAKE TORQUE SPECIFICATIONS...

Page 476: ...429 389 301 404 409 461 464 409 412 464 465 387 391 458 46 382 38 3 4 7 420 465 466 front rear rear 2003 models output shaft brake caliper 1996 1997 models 1998 on models radiatorguard scat side pane...

Page 477: ...ie informa tion 303 304 battery negative terminal 304 capac itor discharge ignition 310 3 14 charging system 304 308 431 436 39 1 394 397 399 246 247 246 247 rear output shaft brake pad replacement 19...

Page 478: ...e andspring strut s pindle suspension and steering control arm handlebar hub 134 174 134 41 42 163 173 174 146 162 162 163 137 141 44 1 141 143 441 45 46 46 47 137 14 I 94 95 202 204 40 41 163 162 163...

Page 479: ...n ition coil stator coil s system diagrams 311 313 troubl eshooting 43 45 438 439 Inspection balan cer shaft 163 control ann upperand lower 377 cooling system 205 crankshaft 162 163 cylinder leak dow...

Page 480: ...rams electric Steering contro l arm handlebar hub front rear specifications shall specifications strutcartridge and spring front strut spindle front tie rods _ tires andwheels troubleshooting wheel fr...

Page 481: ...components I J 3 119 oi l system one w ay check 172 173 Voltage regulator rect ifier 3 10 Wheel and tires front rear Wiring diagram s 378 3 79 379 3 1 363 363 362 3 63 33 1 335 377 37 5 376 469 375 46...

Page 482: ...Headli gh t switch Ignition switch 0 I uni t OH I 1 I J G I I Circuit I I breaker lOA Gd t I ometer light I Hub I safety switch f r b J 10 I_ I t I I t 1 r I Rlgh I J beem 1 dllg hl V I I beo LJ 1 1_...

Page 483: ...d Neut Rw _ Diagram Key Con nectors Ground Frame ground connection N O connection Taill Brake light Voltage regulator Balt ery AUlciliary power connector ClrCUi breaker IDA Starter motor Top motor Cir...

Page 484: ...switch On OH unit On I I On 1 I I H G I i I I Circu it I I I breaker I I IDA I l_ I met er I I light I I I I I I Hub 1 safety switc h 1 _ __ 1__ _ r1 I I l l R19h I t beam _ dllg ht __ __ i _ V I I be...

Page 485: ...tor s Grou nd Frame ground te j connection No con nection 1 _ _ j Br ke TaiV L Fl Brake RUnClng i d light J Volta ge regulator Top motor mounl Auxiliary M pow er conn ector r J Circu it 8 breaker C CU...

Page 486: ...h Ignition switc h Accessory outlet 12V On 0 unit 00 On I I I l f0 r I I o_ I breaker I OA I L_ I C10 I meter 1 r _ _ _ 1 _ T l _ _ _ I 9h I I I am ight r I a l I ighl I I I L i r i I i I a m I Ight...

Page 487: ...High R Neut Front transmission switch low Neut Front AWD Rear AWO hub coil hub coli COl Unit Engi ne temc w Brake TaiU t Brake light Voltag e regulator J l Circuit breaker 20A r Circuit breaker Ignit...

Page 488: ...00 IgnitIon switch speed I S se nsor I 0 0 l I L i unit Circuit breaker 10A Neutral r I I I I I 1 t I f I t I I Acce ssory outlet I HI 00 Ii I I 0 I 0 00 Headlight Engine Over ride Brake switch run o...

Page 489: ...n Rear transmission switc h iII R Neul High ILow 1 Fro nt AWO Rear AWD Front hub coil hub co il transmi ss ion switch cor Unit Engine temp w fo F J Voltage regulator Talll Brake light Battery n Starte...

Page 490: ...er lOA unit l 1 _ AWD Fan Waler temp switch motor sending r r rJ UI I n L I T AWO indicator GL ETC swit ch I Ignition switch On Off 7 t i l i I i d Speedometer 0 Engi ne __ lemp_ DC outlet connectors...

Page 491: ...ar transmi ssion sw itc h HI h R Neut n l Runni ng d Low Neul Front AWD Rear AWD Front hub coli hub coil tran smi ssion switch _ CO l Unit Engi ne temp w 1 c _ IJ L I 1 l_ 1 1 1 Circuli breaker 20A r...

Page 492: ...tch l tllr1 I On On r l 1 H F I I Water temp sending unit Circuit breaker lOA i L _ H i T I I I I 1 1 I I I I I j I Fuse OA r co Off Accessory Acces sory Heacllghl connector plug wrtch Off on Engine o...

Page 493: ...sw itch Root Ro Lo Neul I High I III Diagram Key I Connectors n Ground I e f Frame ground I conneClion Na connection I I _ l I I _ 0 f 1 _ _ 10 61 TaiU t i Brak Ru ng d light Voltage reg ulato r t il...

Page 494: ...R1 9h low beam headlight Hi gh bea m headlight headlig ht I I I I I i I Fuse lOA r f 1 I Rev ace connector 01 Acce ssories _ __ t _ connector Horn sw o ptional on 500 I Horn optio na l o n 500 I I HI...

Page 495: ...transmission switch II High R Neut Front transmission ewnch Low Neut II I I i Front AWe Rear Awe hub coli hub coli COl Unit Engine I lI IIlIIIlIIII I I TailJ Brake light Voltage regulator n I Batlery...

Page 496: ...ad light switch Ig nition switch DC outlet connectors On G 0 unit 1Off 1 W On I l l r I Circuit I breaker l lOA C om el er 1 1 r _ L_ t _ _ _ _ I 1 9h I I am r ighl I am l_ _ I light 1 l I Left Ir am...

Page 497: ...n Diagram Key Connectors Gro und frame ground i II l Rear transmiss ion switch N h N I Low I I e I l I I I Front AWD Rear AWD Front hub co il hub co il transmission switch _ II I I J _ _ _C __D coi l...

Page 498: ...l fu Over ride Brake switch light swit ch I L __ _ _ __ I J f Circ uit I i breaker 20A I I T on U I Lo On on on r Acc esso ry Headli ght Engine Starter plug switch off run switch sw itch J Accessory c...

Page 499: ...NOconnection I Nuul IHlgh e 4 Ne ul Low 1 Front AWO Rear AWD Fro nt hub coli hub coli transmission sw itch 1 foe COl UnIt Eng ine tem p fIJ I z r Tail Brake light Voltage regulator Spark j I plug COl...

Page 500: ...F swi tc h Indicat or switch motor 9 fll I J U f r rt t Waler temp sending unit Circuit breaker lOA I r _ _ _ I I 1 _ _ _ 1 T I II I I I r 1 1 __ _ I Fuse l OA c I I 1 I I H OH W co On OH OH Accessory...

Page 501: ...smission Unit switch swit ch Neut L Neut High II Diag ram Key j Connectors f Ground Frame grou nd f conneClion Na connection f _ B e I TaiU 01 Brak light Running d Voltage regulator _ _oJ J Fus ible l...

Page 502: ...we indIcator Awe switch Oft On Fan motor Waler temp sending ______ 1 I _ __ _ _ R 9 low beam I headlIght High be a I headl ight L O r J low beam hea dl1 9h1 V Fuse I DA IL lo Oft r Horn sw optional on...

Page 503: ...NeUI R l ow Neut High II I t J I I r J I I I I j l ______ _c _ _ 497 Diagram Key Conn ectors Ground Frame grQund connectlon t NO connecllon Tall Brake light I Voltage I regulator l _ J Fusible link i...

Page 504: ...NOTES...

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