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Polaris 2005 Sportsman MV7, Service Manual, Page: 3 / 312

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Polaris 2005 Sportsman MV7 Service Manual Download Page 3

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

Throughout these instructions, important information is brought to your attention by the following symbols:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

DANGER

Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person

inspecting or servicing the ATV.

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or

person inspecting or servicing the ATV.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property

damage.

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies

Loctite, Registered Trademark of the Loctite Corporation

STA-BIL, Registered Trademark of Gold Eagle

FOX, Registered Trademark of Fox Shox

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity Vac, Registered Trademark of Neward Enterprises, Inc.

Ammco, Registered Trademark of Ammco Tools, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Summary of Contents for 2005 Sportsman MV7

Page 1: ...2005 SPORTSMAN MV7 SERVICE MANUAL PN 9919963 2005 SPORTSMAN MV 7 SERVICE MANUAL PN 9919963 Printed in USA 9919963 PART Cvr_9919963 10 19 04 2 43 PM Page 1...

Page 2: ...operations component identification and unit repair along with service specifications for 2005 Polaris Sportsman MV7 ATVs Comments or suggestions about this manual may be directed to Service Publicat...

Page 3: ...ing the ATV CAUTION A CAUTION indicates special precautions that must be taken to avoid personal injury or ATV or property damage NOTE A NOTE provides key information to clarify instructions Trademark...

Page 4: ...X CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10...

Page 5: ...ber Location 1 2 Publications Numbers Replacement Keys 1 3 2005 Sportsman MV7 Dimensions 1 4 1 5 Special Tools 1 6 1 10 Standard Torque Specifications 1 11 Conversion Table 1 12 Tap Drill Charts 1 13...

Page 6: ...No Individual Serial No Body Style Check Digit World Mfg ID This could be either a number or a letter ENGINE SERIAL NUMBER LOCATION Be sure to refer to the engine model number and serial number whene...

Page 7: ...ER NUMBER POLARIS NUMBER Springs Black 9440 P 067 FRAME COLOR All P067 Medium Gloss Black 9440 8520147 Order direct from Midwest Industrial Coatings 952 942 1840 Mix as directed REPLACEMENT KEYS Repla...

Page 8: ...Wheel Base 50 75 in 129 cm Dry Weight 992 lbs 450 kg Gross Vehicle Weight 1700 lbs 771 kg Front Rack Capacity 150 lbs 68 kg Rear Rack Capacity 300 lbs 136 kg Rear rack capacity and tongue weight not...

Page 9: ...YC 035 in 0 9 mm Battery Model Amp Hr 30 Amp Hr Starting Electric Recoil Backup Instrument Cluster LCD Drivetrain Transmission Type Drumshift H L N Rev Park Transmission Capacity 15 2 oz 450m Rear Gea...

Page 10: ...l 4 2870871 Ball Joint Replacement Tool 5 2870623 Shock Absorber Spring Compression Tool 5 2871572 Strut Rod Wrench 5 2871573 LH Strut Spring Compressor 5 2871574 RH Strut Spring Compressor 5 7052069...

Page 11: ...Standard Tools and Engine Tools PU 45432 Caliper or A Basic Caliper Basic Micrometer 2871043 Flywheel Puller 2870773 C Clip Install Tool 2870386 Piston Pin Puller 2871445 Piston Pin Puller Adapter Sta...

Page 12: ...2870588 Hone Oil 12 oz PV 35667 A Cylinder Leak down Tester 2200634 Valve Seat Reconditioning Kit Clutch PVT Tools 2870506 Drive Clutch Puller 2870913 Driven Clutch Puller 2872292 EBS Clutch Align To...

Page 13: ...lacement Kit 2870338 Spider Nut Socket 2871358 Clutch Holding Fixture 2871025 Clutch Bushing Replace Tool Kit Suspension Tools 2870871 ATV Ball Joint Tool Kit 2871071 Shock Body Holding Tool 2870623 S...

Page 14: ...ctrical Tools PV 43568 Fluket 77 Multimeter PV 39617 Current Clamp 2870836 Battery Hydrometer 8712500 Tachometer RPM PV 39951 A Tachometer Electrical Tools 2870630 Timing Light 2871745 Static Timing L...

Page 15: ...27 3 1 43 5 0 60 6 9 10 32 31 3 6 49 5 6 68 7 8 Torque ft lbs Nm 1 4 20 5 7 8 11 12 16 1 4 28 6 8 10 14 14 19 5 16 18 11 15 17 23 25 35 5 16 24 12 16 19 26 29 40 3 8 16 20 27 30 40 45 62 3 8 24 23 32...

Page 16: ...ubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp...

Page 17: ...11 32 R 3 8 13 32 13 32 0 0995 0 0937 0 1285 0 125 0 166 0 161 0 196 0 234 0 277 0 265 0 3125 0 3125 0 3437 0 339 0 375 0 406 0 406 3 32 3 32 1 8 1 8 11 64 5 32 13 64 15 64 9 32 17 64 5 16 5 16 11 32...

Page 18: ...the end of a lever one meter in length applied in a rotational direction l or ltr Liter Left Side Always referred to based on normal operating position of the driver m Meter meters Mag Magneto Magnet...

Page 19: ...ts 2 14 2 16 Fuel System 2 17 2 18 Compression Test 2 18 2 19 Battery Maintenance 2 19 2 20 Ignition 2 19 2 20 Coolant System Maintenance 2 21 2 23 Air Box Filter Service 2 23 2 24 Breather Filter Lin...

Page 20: ...il level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key The following symbols denote potential items...

Page 21: ...ry 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if re placing E Air filter main element Weekly Inspect replace as needed Recoil housing if applicable Weekly Drain water as...

Page 22: ...e Cable ETC Switch 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary J E Choke cable 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50...

Page 23: ...ect replace as needed J E Ignition Timing 100 H 12 M 620 1000 Inspect Wiring 100 H 12 M 620 1000 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc J Cl...

Page 24: ...ont Winch Front Storage Rack Gas Cap Gear Shifter Brake Lever Ignition Key Choke Winch Switch Instrument Cluster Speedometer Light Control Run Switch Reverse Override Throttle AWD Switch Winch Selecti...

Page 25: ...2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count Part No Description Additives Sealants Thread Locking Agents Misc 2870585 Loctitet Primer N Aerosol 25 g 2871956 Loctitet Thre...

Page 26: ...enance Kits can be purchased at your local Polaris dealer 2202166 Sportsman 600 700 Oil Change Kit Oil Filter 2 Qts of 0W 40 oil Instruction Sheet 2859066 Sportsman 600 700 Maintenance Kit Oil Filter...

Page 27: ...er level Change after 1st month 6 months or 100 hours thereafter Change more often 25 50 hours in extremely dirty condi tions or short trip cold weather operation 2 Transmis sion Polaris AGL Gear case...

Page 28: ...2 such as Polaris Premium All Season Grease Conoco Superlube M or Mobilegrease Special PRE RIDE DAILY INSPECTION Perform the following pre ride inspection daily and when servicing the vehicle at each...

Page 29: ...lubricant level The front and rear gearcase lubricant level cannot be checked with a dipstick The gearcase must be drained and re filled with the proper amount of lubricant Refer to procedures To cha...

Page 30: ...and fill plug use a 5 16 hex for removal and installation To change lubricant 1 Remove transmission drain plug to drain the oil Catch and discard used oil properly 2 Clean and reinstall the drain plu...

Page 31: ...e Use the side fill plug when checking or changing oil 1 Position the vehicle on a level surface Fill Plug ILL 1 2 Remove the side fill plug and view the oil level through the fill plug hole 3 Add lub...

Page 32: ...pivot bushings and replace if worn or damaged Lubricate the tie rod ends with a light aerosol lubricant or grease 2 Note orientation of tie rod end studs with the ends that are up down vertical Remove...

Page 33: ...htening clockwise the jam nut under the rubber boot between the choke knob and nut Firmly grasp the rubber boot and tighten until the choke slides freely but stays out when pulled Verify free play of...

Page 34: ...JUSTMENT 1 Slide boot off throttle cable adjuster and jam nut 2 Place shift selector in neutral and set parking brake THROTTLE CABLE ELECTRONIC THROTTLE CONTROL ETC SWITCH ADJUSTMENT CONTEND 3 Start e...

Page 35: ...ot Severe burns may result FUEL VALVE AND FUEL TANKS The fuel valve 1 is located on the left side panel OFF Turn the fuel valve off for vehicle storage and when transporting REAR TANK It is recommende...

Page 36: ...age NOTE The bowl drain screw is located on the bottom left side of the float bowl 1 Turn fuel valve to the off position 2 Place a clean container beneath the bowl drain spigot or bowl drain hose 3 Tu...

Page 37: ...or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician im mediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Kee...

Page 38: ...t and then the negative black cable 9 Reattach vent hose making sure it is properly routed and not kinked or pinched 10 Coat terminals and bolt threads with Dielectric Grease PN 2871329 11 Reinstall b...

Page 39: ...tselfoftrappedair Observe coolant levels often during the break in period G Overheating of engine could occur if air is not fully purged from system G PolarisPremium60 40anti freezeis premixed and rea...

Page 40: ...pper and lower marks on the coolant reservoir If it is not 1 Remove the side panel Refer to Chapter 5 2 Remove reservoir cap Verify the inner splash cap vent hole is clear and open 3 Fill reservoir to...

Page 41: ...OTE When reinstalling seat make sure the slots in the seat engage the tabs in the fuel tank 3 Remove clips A from air box cover and remove cover Inspect the gasket It should adhere tightly to the cove...

Page 42: ...heck the air box drain tube located toward the rear of the machine Drain whenever deposits are visible in the clear tube 1 Remove drain plug from end of sediment tube 2 Drain tube 3 Reinstall drain pl...

Page 43: ...rating the ATV in very wet conditions This should also be done before storing the ATV The drain screw is located at the bottom of the recoil housing Remove the screw with a 10 mm wrench Reinstall scre...

Page 44: ...o dry out the PVT system shift the transmission to neutral and rev engine slightly to expel the moisture and air dry the belt and clutches Allow engine RPM to settle to idle speed shift transmission t...

Page 45: ...tion Always read top side of dipstick to properly check oil level in crankcase Dipstick NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture...

Page 46: ...mark on the dipstick 16 Dispose of used filter and oil properly STEERING The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Also check to make sure...

Page 47: ...eel nuts or loose front hub components Check for Loose Wheel or Hub G Refer to the Body Steering Chapter 5 or Final Drive Chapter 7 for service procedures CAMBER AND CASTER The camber and caster are n...

Page 48: ...3 to 6 cm wider than the measurement at the rear B Chalk Line Measurement A Measurement B Ill 1 TOE ALIGNMENT ADJUSTMENT If toe alignment is incorrect measure the distance between vehicle center and...

Page 49: ...the engine and allow the arrestor to cool 8 Reinstall the clean out plugs WARNING G Do not perform clean out immediately after the engine has been run as the ex haust system becomes very hot Serious b...

Page 50: ...ssive travel or spongy feel G Check friction pads for wear damage or looseness G Check surface condition of the disc G Inspect thickness of brake pad friction material BRAKE PAD INSPECTION Pads should...

Page 51: ...ystem and adjust or bleed if necessary First check foot brake effectiveness by applying 50lb approx downward force on the pedal The top of the pedal should be at least 1 inch 25 4mm above the surface...

Page 52: ...eck all rear suspension components for wear or damage G Inspect shock for leakage CV SHAFT BOOT INSPECTION Inspect the cv shaft boots in the front and rear of the ATV for damage tears wear or leaking...

Page 53: ...Elevate the side of the vehicle by placing a suitable stand under the footrest frame A 4 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION 1 With the transmission in Park and the parking b...

Page 54: ...less FRAME NUTS BOLTS FASTENERS Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques...

Page 55: ...ontrol The winch control located on the side of the winch gives the operator easy access to switch between ENGAGED and FREESPOOL When the winch is ENGAGED the winch only allows the cable to be pulled...

Page 56: ...p type cleaners only High pressure washers may force water past seals Stabilize the Fuel Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions o...

Page 57: ...battery from the vehicle and ensure that it s fully charged before placing it in storage See Chapter 10 for instructions Engine Anti Freeze Test engine coolant strength and change if necessary Coolant...

Page 58: ...MAINTENANCE 2 40 MAINTENANCE SCHEDULE Service Date Hours Miles Service Performed Serviced By...

Page 59: ...22 Combustion Chamber 3 22 Valve Seat Reconditioning 3 23 3 25 Cylinder Head Assembly 3 25 Valve Sealing Test 3 26 Valve Train Exploded View 3 26 Engine Head Reassembly 3 27 3 29 Cylinder Removal 3 2...

Page 60: ...g Washer Journal Bearings Baffle NOTE If needed heat the oil baffle bolts with a heat gun to remove 60 6 in lbs 6 8 68 Nm 60 6 in lbs 6 8 68 Nm Oil Pickup O ring Crankshaft Ball Bearing Bushing Flange...

Page 61: ...3 Nm Bolt Oil Gerotor OIL OIL Oil Pump Oil Pump Bolts 84 8 in lbs 9 5 90 Nm 1 2 3 4 Oil Pump Bolt Tighten Sequence Mag Gasket Cover No Grease on this portion of gasket Gear Stator Cover Wire Hold Dow...

Page 62: ...1 35 Nm 84 8 ft lbs 9 50 0 9 Nm Bolts Tighten Top Bolt First 1 2 Oil Filter 50 5 in lbs 5 65 0 56 Nm Apply Polaris 0W 40 oil to seal OIL Oil Filter Nipple 35 4 ft lbs 47 5 5 4 Nm Hex Plug 216 24 in lb...

Page 63: ...ply Moly Lube grease to valve tips 2 Gasket 3 Gasket free of oil Verify tabs are visible 3 Pushrods Bushing Expansion Plug Cylinder Apply Polaris 0W 40 oil OIL 4 4 Apply thin film of 0W 40 to 25 55 mm...

Page 64: ...ts Spark Plugs 216 24 in lbs 24 5 2 7 Nm O ring Seal Carburetor Boot 216 24 in lbs 24 5 2 7 Nm Bolts Boot Clamp 20 5 in lbs 2 5 0 55 Nm BST34 Carburetor Vent Line Exhaust Manifold Gasket Bolts 216 24...

Page 65: ...LE COMPONENTS The following components can be serviced or removed with the engine installed in the frame S Flywheel S Alternator Stator S Starter Motor Starter Drive S Cylinder Head S Cylinder S Pisto...

Page 66: ...t Crankcase 12 mm 192 24 21 7 2 7 Oil Fill Tube Bolt 5 mm 50 5 5 64 0 56 Oil Filter Pipe Fitting 20 mm 35 4 47 5 5 4 Oil Pick Up 5 mm 60 6 6 8 0 68 Oil Pressure Relief Plug 10 mm 22 2 30 3 Oil Pump Ho...

Page 67: ...lined below CRANKCASE BOLT TIGHTEN SEQUENCE 3 1 5 6 2 4 Lubricate threads and between washer and underside of bolt with engine oil Torque in sequence to spec provided allow the gasket to set for 1 min...

Page 68: ...age limit 0 00394 0 1 mm y Head Standard height 3 478 88 35 mm Valve Seat Contacting width In Std 0 0472 0 00787 0 0039 1 20 0 20 0 10 mm Ex Std 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Seat Angle Std...

Page 69: ...n Piston ring installed Top ring Piston Ring Piston ring installed gap Top ring Limit 0 01181 0 00393 0 30 0 10 mm g g Second Second ring Limit 0 01476 0 00492 0 375 0 125 mm Oil ring Oil ring Limit 0...

Page 70: ...arpage limit 0 00394 0 1 mm y Head Standard height 3 478 88 35 mm Valve Seat Contacting width In Std 0 0472 0 00787 0 0039 1 20 0 20 0 10 mm Ex Std 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Seat Angle S...

Page 71: ...Piston Piston ring installed Top ring Piston Ring Piston ring installed gap Top ring Limit 0 01083 0 00295 0 275 0 075 mm g g Second Second ring Limit 0 0177 0 00394 0 45 0 10 mm Oil ring Oil ring Lim...

Page 72: ...ooling systems and comes pre mixed ready to use Radiator Thermostat Cylinder Head Water Pump Cylinder FLOW COOLING SYSTEM WARNING Never remove radiator cap when engine is warm or hot The cooling syste...

Page 73: ...ct the coolant hoses Properly dispose of any antifreeze from the engine or hoses 13 Refer to PVT System Chapter 6 to remove outer clutch cover drive belt drive clutch driven clutch and inner cover D 1...

Page 74: ...serve coolant level in the radiator Allow air to purge and top off as necessary Reinstall radiator cap and bring engine to operating temperature After engine is cool check level in reservoir tank and...

Page 75: ...for correct cross hatch NOTE Do not allow cylinder to heat up during honing S After honing has been completed inspect cylinder for thinning or peeling If cylinder wear or damage is excessive it will...

Page 76: ...e first path entering the camshaft bores onto the rear balance shaft journal and then draining back into the crankcase sump The second oil path from the main oil galley feeds the lifter bores and then...

Page 77: ...orkingwith compressed air to prevent personal injury 3 Check the ends of the push rods A for nicks grooves roughness or excessive wear 4 The push rods A can be visually checked for straightness while...

Page 78: ...d is still on the engine Keep all parts in order with respect to their location in the cylinder head WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly 1 Havi...

Page 79: ...of specification Valve Spring Free Length Valve Spring Length Std 1 827I 46 40 mm Installed Height 1 47 37 34 mm 6 Remove valve guide seals IMPORTANT It is recommended to replace seals whenever the c...

Page 80: ...valve stem with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications Valve Stem Diameter Intake 0 2356 0 00039 5 985 0 01 mm Exhaust...

Page 81: ...the valve seat cutters in the Cylinder Head Reconditioning Kit PN 2200634 Abrasive stone seat reconditioning equipment can also be used Keep all valves in order with their respective seat NOTE Valve...

Page 82: ...hould contact the middle of the valve face or slightly above and must be the proper width S If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too...

Page 83: ...the other valve s 12 Thoroughly clean cylinder head and valves CYLINDER HEAD REASSEMBLY NOTE Assemble the valves one at atime tomaintain proper order 1 Apply engine oil to valve guides and seats 2 Coa...

Page 84: ...n solvent onto the intake port and check for leakage around each intake valve The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into exhaust port A VALVE T...

Page 85: ...5 Nm in sequence provided Pg 3 9 Allow the gasket to set for 1 minute at this torque then turn bolts 90 1 4 turn in sequence Refer to Page 3 9 for tightening sequence C Cylinder Head Bolt Torque Allo...

Page 86: ...N 2870585 to remove any debris This will ensure proper sealing when installing bolts 10 Install rocker cover Torque bolts to 84 8 in lbs 9 5 0 9 Nm See Page 3 6 for proper torque sequence Rocker Cover...

Page 87: ...g engine reassembly Mark the Hydraulic Lifter 4 Check the lifters for wear or scores 5 Check the bottom end of lifter to make sure that it has a slight convex 6 If the bottom surface has worn flat it...

Page 88: ...nd ring 5 Remove the oil control ring The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section The top rail has a locating tab on the end wh...

Page 89: ...p of Cylinder 1 2 Up From Bottom X X Y Y X Y 5 Record measurements If cylinder is tapered or out of round beyond 002 the cylinder must be replaced Cylinder Taper Limit 002I 05mm Max Cylinder Out of Ro...

Page 90: ...0 005 mm 700 0 00059 0 0002 0 015 0 005 mm 2 Measure piston pin O D Replace piston and or piston pin if out of tolerance Piston Pin Measurement Locations Piston Pin O D 0 7874 7872 20 19 995 mm 3 Mea...

Page 91: ...0 0177 00984 0 45 0 25 mm 600 700 NOTE Ring should be installed with the mark on the ring facing upward 2 Measure installed gap with a feeler gauge C at both the top and bottom of the cylinder REMINDE...

Page 92: ...e damaged 3 Remove starter bendix assembly A Note the thrust washers located on both sides of the bendix B 4 Inspect the thrust washer for wear or damage and replace if necessary 5 After the bendix is...

Page 93: ...or stator coils may be damaged 2871043 A 5 Use caution when removing the wire holddown B trigger coil C and the stator assembly D Do not tap or bump the gear stator housing cover or the stator This c...

Page 94: ...n the areas of the lower recoil housing that have sealant on them before reinstallation After the areas are clean and dry apply Loctite Pipe Sealant PN 2871956 to the same areas Install lower recoil h...

Page 95: ...g Recoil Pulley 3 Screws Sportsman MV with Recoil 2 On a standard Sportsman 700 remove the stator cover A and water pump cover B B A Standard Sportsman 700 3 Remove the nylok nut C washer D and water...

Page 96: ...ensure proper gear alignment and timing during reassembly of the gears Timing Marks K M N Water Pump Gear NOTE If replacing one of the gears it is recommended that all of the gears be replaced A gear...

Page 97: ...gear The springs should stay in place CAUTION WEAR SAFETY GLASSES AT ALL TIMES USE CAUTION WHEN WORKING WITH THE TOP GEAR THE SPRINGS COULD CAUSE INJURY OR BECOME LOST SHOULD THEY POP OUT 13 Remove a...

Page 98: ...lign the three gear tabs during the next step PU 45497 1 Cam Gear Spring Installation Tool Kit PU 45497 Tapered Pins PU 45497 1 Cam Gear Tooth Align Tool PU 45497 2 19 Line up the two gears using the...

Page 99: ...er Wrench PU 45498 is only needed to rotate the camshaft when the entire valve train is assembled If the rocker arms are removed the cam shaft can be turned by hand 23 Remove the bolt and nut from the...

Page 100: ...ement rotors will fit into the old oil water pump housing Oil Rotor Clearance 29 Use a feeler gauge to measure the clearance between the two rotors Measure the gap between the two rotor tips as shown...

Page 101: ...ate safety gear during this procedure Protective gloves clothing and eyewear are required 32 Carefully press the gear off the assembly while supporting the housing assembly Press off gear 33 Remove th...

Page 102: ...rting the housing CRANKCASE DISASSEMBLY CONT D 38 Remove thrust plate U U 39 Remove PTO end engine mount Remove crankcase bolts Tap on the reinforced areas on the cases using soft hammer Carefully sep...

Page 103: ...ings anytime the engine is disassembled CAMSHAFT INSPECTION 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage Lobe height 3 Measure height of each cam lobe u...

Page 104: ...After any reassembly or rebuild the engine must be primed using the Oil Priming Adapter PU 45778 and a 3 4 full oil filter before initial start up Follow Steps 45 46 in this section to properly prime...

Page 105: ...ef hole E 7 Assemble the crankcase halves Apply LocTitet 242 PN 2871949 to the threads and pipe sealant to the bolt flanges Torque bolts to 22 2 ft lbs 30 3 Nm following torque pattern on Page 3 9 Cra...

Page 106: ...tion 13 Install piston assemblies into cylinder aligning the piston pin holes to ensure proper alignment of the pistons to the connecting rods upon assembly Partially install the piston pins into the...

Page 107: ...oly lube lubriplate or oil to the rotors on the oil pump shaft NOTE The application of oil or lubriplate aids in priming the oil pump during initial engine start up Lubricate Rotors 19 Align the bolt...

Page 108: ...haft gear to 250 F 121 C on a hot plate J I J CAUTION The crankshaft gear is extremely hot Severe burns or injury can occur if the gear is not handled with extreme care and caution Follow the procedur...

Page 109: ...ove the camshaft gear and tool Use the Cam Spanner Wrench PU 45498 to rotate the cam to the proper position NOTE Cam Spanner Wrench PU 45498 is only needed to rotate the camshaft when the entire valve...

Page 110: ...eal cannot be removed or installed with the gear stator housing attached to the engine Shaft damage will occur NOTE Install the waterpump seal N with the seal lip facing out towards the crankcase Use...

Page 111: ...d or damaged PA 45658 32 Before installing the gear stator housing cover install the Water Pump Seal Saver PA 45401 onto the water pump shaft PA 45401 33 Install the new gasket to the gear stator hous...

Page 112: ...PA 45401 PA 45658 O Gear Stator Housing Bolt Torque 96 12 in lbs 10 85 0 35 Nm Torque in Proper Sequence Pg 3 3 NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove...

Page 113: ...olts New bolts contain patch lock Torque bolts to 96 12 in lbs 10 85 0 35 Nm and follow the proper bolt torque sequence on Pg 3 3 Coat the stator wire grommet U with Nyogelt Grease PN 2871329 NOTE Be...

Page 114: ...4 49 After the engine is completely assembled and ready for installation the engine must be properly primed with Polaris 0W 40 Synthetic Oil PN 2871281 Fill the oil filter three quarters full with Po...

Page 115: ...ed approximately 12 18 Check handle c ring for proper tension and the handle for cracks or damage which may allow water or dirt to enter the recoil housing through the rope NOTE The handle must seal t...

Page 116: ...l will not pass through fuel valve S Fuel pump inoperative restricted S Tank vent plugged or pinched S Carb starter circuit plugged S Engine flooded S Low compression high cylinder leakage S No spark...

Page 117: ...ap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key S Poor connections in ignition system S Valve sticking S Air leaks in intak...

Page 118: ...will aid in purging the system of air Pump the hose using your hand several times as shown in the diagram Elevating the rear of the ATV with a floor jack rear tires 4 6 off the ground also aids the pu...

Page 119: ...umbers 4 4 CV Carburetor System Function 4 Cycle 4 5 CV Carburetor Vent System 4 Cycle 4 5 CV Carburetor Operation 4 5 4 8 Disassembly Notes CV Carburetor 4 8 4 10 Cleaning CV Carburetor 4 9 Inspectio...

Page 120: ...Cap 17 Float Pin 18 Plate 19 O ring 20 Screw 21 Float Body Assy 22 Screw 23 Float Assy 24 Screw 25 Needle Valve 26 O ring 27 Pilot Jet 28 O ring 29 Washer 30 Spring 31 Adjuster 32 Adjuster Screw 33 R...

Page 121: ...Foil Fuel Outlet Tank Fuel Cap Vent NOTE Located under rear rack See Chapter 5 for rear tank removal Foam Fuel Fitting Foil Fuel Valve Knob Brackets 3 Way Valve Fuel Sender Vent Line Fuel Lines Tank...

Page 122: ...t Fitting Screens L L Located Above Oil Tank FUEL FLOW Fuel Flow Diagram Valve to Pump Line Impulse Line Pump to Carburetor Line Fuel Filter Carburetor Vent Line Front Fuel Tank Fuel Pump FRONT TANK O...

Page 123: ...0 6000 ft 0 1800 meters and ambient temperatures between 40 and 80 F 5 to 26 C Carburetors must be re calibrated if operated outside this temperature and or altitude range The jetting installed in pro...

Page 124: ...id range and high throttle settings 1 4 to full throttle VENT SYSTEMS CV CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl The lines must be free of kinks r...

Page 125: ...ikuni BST carburetor PILOT IDLE AND SLOW SYSTEM This system supplies fuel during engine operation with throttle valve closed 1 or slightly opened The fuel from float chamber 2 is metered by pilot jet...

Page 126: ...r the needle valve admits and shuts off fuel alternately to maintain a practically constant fuel level inside the float chamber Inlet Pipe 1 4 2 3 MAIN SYSTEM As throttle valve 1 is opened engine spee...

Page 127: ...led Brass Plug Removed CARBURETOR DISASSEMBLY MIKUNI CV Use the following disassembly assembly and inspection techniques to service a CV carburetor 1 Remove carburetor diaphragm chamber cover with a r...

Page 128: ...fuel residue and varnish soak for short periods only in carburetor cleaner and rinse in hot water 3 Replace the jets if they have a buildup of fuel residue or bacterial growth that cannot be removed...

Page 129: ...ation or damage Make sure the diaphragm is pliable but not swollen The diaphragm should fit properly in the carburetor body Replace diaphragm assembly if diaphragm is damaged E D C A B 3 Replace parts...

Page 130: ...the inlet needle valve pin without compressing the spring Float Height Std 13 14 mm 51 55 in 2 Measure the height from the float bowl mating surface to the top of step in float as shown Both sides of...

Page 131: ...off 2 Disconnect impulse line from pump 3 Connect Mity Vact PN 2870975 to the impulse line fitting on the pump 4 Apply 5 inches Hg vacuum to the pump fitting The diaphragm should hold vacuum indefini...

Page 132: ...that secure the fuel sender to the tank 7 Slowly lift the sender out of the tank Lift the sender out at an angle so the float will more easily come out of the fuel tank Fuel Sender Installation 1 Rei...

Page 133: ...Choke plunger sticking incorrectly adjusted choke S Choke cable binding or improperly routed S Incorrect pilot air fuel screw adjustment S Faulty inlet needle and seat S Faulty inlet needle seat O Ri...

Page 134: ...FUEL SYSTEM CARBURETION 4 16 NOTES...

Page 135: ...k Brushguard Removal Install 5 8 5 10 Warn Winch Removal Installation 5 10 5 12 Headlight Pod Exploded View 5 13 Handlebar Block Installation Procedure 5 14 Body Assembly Exploded View 5 15 5 17 Steer...

Page 136: ...location of components SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870871 Ball Joint Replacement Tool 2870872 Shock Spanner Wrench 2870623 Shock Absorber Spring Compression Tool 2871572 Strut Rod Wren...

Page 137: ...ter installation The inside insert A should be flush with the top of the outside insert B A B SIDE PANEL REMOVAL Side panel removal is quick and easy use the following instructions for removal and ins...

Page 138: ...o the slots Reinstall cover shield PLASTIC FOOT WELL REMOVAL INSTALLATION 1 Remove the four plastic inserts A that secure the wheel well to the front and rear cabs See PLASTIC INSERT REMOVAL INSTALLAT...

Page 139: ...thout the frame tube supports attached 3 To remove with out the frame tube supports remove the four T 27 torx screws A Slide the footwell plate off of the frame A Reassembly 14 16 ft lbs 19 22 Nm 4 To...

Page 140: ...16 ft lbs 19 22 Nm 4 Remove the T 27 screws C that secure the tube rack supports to the rear corner of the front rack each side Reassembly 14 16 ft lbs 19 22 Nm C C 5 Remove the two T 27 torx screws C...

Page 141: ...Disconnect the lower headlight wiring harnesses 3 Disconnect the winch wiring harness Remove Harness 4 Remove the side vent shields C if needed C Reassembly 14 16 ft lbs 19 22 Nm 5 Remove the bolts B...

Page 142: ...emove two rear bolts B that secure the rear rack to the frame 14 16 ft lbs 19 22 Nm for Reassembly A Reassembly 14 16 ft lbs 19 22 Nm 4 Remove the T 27 bolt and nut C that secure the rack to the rear...

Page 143: ...ar Top Rack Already Removed 1 If you have already removed the rear top rack proceed with removing the rear brushguard to main frame bolts A on each side A Reassembly 18 ft lbs 24 Nm 2 For reassembly o...

Page 144: ...T WARN WINCH 1 Disconnect the negative battery cable from the battery 2 Disconnect wires from the Warn winch or disconnect the quick connect harness A located above the radiator Access can be gained t...

Page 145: ...E F Reassembly 18 ft lbs 24 Nm Hook 10 Reverse the steps of removal for installation WARN WINCH CONTACTOR LOCATION Both the front and rear winch contactor are located under the left rear fender Winch...

Page 146: ...mount as shown Route the wire between the switch mounting bracket and the master cylinder clamp next to the front spacer 3 Reposition the spacers between the switch mounting bracket and the master cyl...

Page 147: ...r S Remove two screws securing bottom half of pod E Assembly S Install bottom of pod onto handlebar and secure to brackets S Install key switch choke cable and headlight S Connect 12V power outlet whe...

Page 148: ...Nm Install and Torque Front Bolts First NOTE There will be a slight gap on the backside of the blocks after the procedure is performed 2 The bottom handle bar block has a side with 3 holes the side w...

Page 149: ...y Front Cab Assembly Seat Latch Release Rear Cab Side Cover Front Cover Front Cab Seat Pull UP on rear of seat and back to disengage tabs at front of seat Splash Shields Frame Frame Seat Latch Side Co...

Page 150: ...DY RACK BUMPER EXPLODED VIEW A Front Rack Platform B Corner Support Bracket C Rubber Bumper D Side Vent E Headlight F Front Brushguard G Access Door H Front Rack Support I Front Brush Guard Mount J Wa...

Page 151: ...A Rear Rack B Rear Brush Guard C Rear Platform Mount D Warn Winch E Corner Bracket F Storage Container A B C D A Rear Rack B Front Rack C Outside Support Tubes D Outside Footwell Plate E Footwell Pla...

Page 152: ...7 19 Nm 40 45 ft lbs 54 61 Nm Steering Post Steering Post Arm Frog 1 2 NOTE To avoid damage to tie rods and other steering components be sure to install tie rod end bolts in the proper direction The s...

Page 153: ...WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 9 Attach A arm to...

Page 154: ...17 ft lbs 24 Nm Stabilizer Support 35 ft lbs 48 Nm 30 ft lbs 41 Nm 30 ft lbs 41 Nm Lower Control Arm Orientate Bushings Correctly Rear Front Bushing Orientation 1 1 1 Upper Control Arm 35 ft lbs 48 N...

Page 155: ...ion guide for recommended service intervals 15 ft lbs 21 Nm Nut 15 ft lbs 21 Nm 18 ft lbs 25 Nm Washer Upper Pivot Ball Lower Pivot Ball Spacer Rubber Spring Retainer Spring Bolt Spacer Nut Washer Cla...

Page 156: ...orque 15 ft lbs 21 Nm BALL JOINT REPLACEMENT NOTE Refer to the illustration on the previous page for this procedure 1 Loosen front wheel nuts slightly 2 Elevate and safely support machine under footre...

Page 157: ...s that are sometimes left after a fender or cab is bent flexed or damaged WARNING The following procedure involves the use of an open flame Perform this procedure in a well ventilated area away from g...

Page 158: ...BODY STEERING SUSPENSION 5 24 NOTES...

Page 159: ...Install 6 6 PVT Disassembly 6 7 PVT Assembly Inspection 6 8 Drive Clutch Spring Specifications 6 9 Shift Weights Inspection 6 10 6 11 Drive Clutch Disassembly Inspection 6 11 6 13 Drive Clutch Reassem...

Page 160: ...Mark with permanent marker before disassembly One way clutch PVT SEALING AND DUCTING COMPONENTS Clutch Cover Clutch Inlet Duct Clamps Clutch Cover Seal Seal Retainer Bracket Inner Cover Seal Transmiss...

Page 161: ...ve Clutch 2 The Driven Clutch and 3 The Drive Belt The internal components of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the dev...

Page 162: ...set Belt Width See Page 6 16 6 18 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs See Pag...

Page 163: ...Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and...

Page 164: ...r should now be accessible If necessary remove the rear right cab assembly Remove the three plastic inserts that secure the rear cab to the frame Remove the seat latch bolt also See PLASTIC INSERT REM...

Page 165: ...t removal 6 Remove drive clutch retaining bolt and remove drive clutch using puller Drive Clutch Puller PN 2870506 Clutch Holding Wrench PN 9314177 7 Remove driven clutch retaining bolt and driven clu...

Page 166: ...B C Inner Cover Bolt Torque Rear 12 ft lbs 16 6 Nm Driven Clutch Retaining Bolt Torque 17 ft lbs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 ft lbs 55 Nm 7 Install clutch offset spacer s on transmis...

Page 167: ...its compression rate This may result in complete stacking of the coils and subsequent clutch component failure Measuring Spring Length With the spring resting on a flat surface measure its free length...

Page 168: ...weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance clutch balance engagement and shifting characteristics PN 5630...

Page 169: ...y a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision bala...

Page 170: ...g if more brass than Teflont is visible on the bushing Refer to bushing replace ment in this chapter 4 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch asse...

Page 171: ...lace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 4 Rubber backed buttons can and should be usedin all ATV clutches if the hollow rolle...

Page 172: ...Nut Socket PN 2870338 Torque to 15 ft lbs Reinstall shift weights using new lock nuts on the bolts 6 Reinstall clutch spring Engine Rotation Nut on trailing side 7 Reinstall cover aligning bosses on t...

Page 173: ...4 1 188 2 98 3 02 cm Wear Limit 1 125 2 86 cm 5 Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Replace if necessary 6 Inspect belt for hour glassing extreme ci...

Page 174: ...tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 NOTE If the distance is greater than 1 8 or less than 1 16 clutch alignment must be adjusted as follows 3 Remove...

Page 175: ...E WAY CLUTCH INSPECTION DRIVE CLUTCH 1 Rotate one way clutch clockwise as viewed from the cover plate side The clutch should rotate on the shaft with only slight amount of drag Verify there is no bind...

Page 176: ...washer for damage Measure the thickness and compare to specification Replace if worn or damaged PTFE Washer Thickness Standard 030 76mm Service Limit 025 64mm MOVEABLE SHEAVE BUSHING INSPECTION 1 Insp...

Page 177: ...roviding instant EBS braking Engine braking EBS continues until the drive clutch speed exceeds the one way clutch speed or until the throttle is applied and the engine reaches clutch engagement speed...

Page 178: ...wind B C SPIDER DISASSEMBLY 6 Remove the inside spider plate D and spider dampener E Inspect the spider dampener E for wear and replaced if needed E D 7 Remove the E clip F washer G and the clutch rol...

Page 179: ...spect the bearing for wear Spin the bearing if the bearing does not spin smoothly replace as needed To remove the bearing simply press the bearing from the shaft 13 Inspect BOTH sheaves for signs of w...

Page 180: ...earing into the outer sheave 3 Install the small and large retaining rings into the outer sheave above the bearing 4 Line up the X on the moveable sheave with the X on the stationary sheave or use the...

Page 181: ...tall the clutch rollers D onto each side of the outside spider Install the washers E and E clips F to secure the rollers Spin the roller the rollers should spin freely 11 Install the spider dampener G...

Page 182: ...Retaining Ring 15 Install the cam assembly helix over the shaft Line up the X on the cam X on spider and X on the stationary sheave or use the marks previously made before disassembly NOTE If the cam...

Page 183: ...lip 5 Washer 6 Roller 7 Outer Spider 8 Spring 9 Shaft 10 Thrust Washer 11 Moveable Sheave 12 Roller Pin 13 Spring Pin 14 Stationary Sheave 15 Bearing 16 Retaining Ring 17 Retaining Ring 18 Inner Spide...

Page 184: ...Nut C 6 With towers pointing toward the vise slidesheave onto puller rod 7 Install removal tool Item A B into center of sheave with A side toward sheave 8 Install nut C onto end of puller rod and hand...

Page 185: ...d placing outside of cover toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seat...

Page 186: ...on cover Clutches or weight being applied to cover while in operation Use of High vs low range Clear obstruction Inspect system Clean repair or replace as necessary Seal PVT system ducts Remove weight...

Page 187: ...ront Prop Shaft Removal 7 6 U Joint Disassemble Assemble 7 6 7 7 Drive Axle Propshaft Exploded View 7 8 AWD Front Gearcase Operation 7 9 AWD Front Gearcase Service 7 9 7 17 Rear Hub Remove Install 7 1...

Page 188: ...oot Clamp Pliers 2870772 1 3 4 Straight Wrench FRONT DRIVE AXLE REMOVAL 1 Set the ATV in park Remove hub dust cap 2 Remove cotter pin 3 Loosen the hub retaining nut 4 Loosen but do not remove the whee...

Page 189: ...e shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer 2 Install drive shaft in strut 3 Install lower ball joint torque nut to 25 ft lbs 34 5 Nm and install...

Page 190: ...CV boot replacement requires 3 5 oz of grease 8 Before installing the new boot remove all grease from the boot area and shaft NOTE It is very important to use thecorrect typeand quantity of grease Us...

Page 191: ...lose tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothl...

Page 192: ...to remove the pins from both front drive axles U JOINT DISASSEMBLY CAUTION Always wear eye protection 1 Remove internal or external snap ring from all bearing caps NOTE If yoke or bearing is removed c...

Page 193: ...side Continually check for free movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure for other side 4 Install outer yoke...

Page 194: ...earcase Propshaft Assembly Inner CV Joint Circlip Circlip Inner Boot Outer Boot Front Drive Boot Replacement Kits Outer Clamp Boot Inner Clamp 3 5 oz Grease 3 5 oz NOTE Refer to your parts manual for...

Page 195: ...to a roller cage that contains 14 rollers and roller cam The difference in rpm by input shaft and front axles the forces the rollers up the external cam The rollers engage themselves to the output hu...

Page 196: ...front gearcase Replace the circlip on the driveshaft end for reassembly 10 Remove the roller pin from the front prop shaft Use the Roller Pin Removal Tool PN 2872608 11 Remove bolts securing bottom of...

Page 197: ...broken or missing teeth 5 Remove the roll cage assembly rollers and H springs 6 Thoroughly clean all parts Inspect the rollers A for nicks and scratches The rollers must slide up and down freely withi...

Page 198: ...he thrust bearing F and the dowel H G F H 13 Inspect the magnetic coil I in the output housing NOTE See FRONT GEARCASE DIAGNOSIS later in this chapter for more details on the coil 14 Inspect the back...

Page 199: ...ess the pinion shaft seal into the pinion cover until the seal is flush with the sealing surface 3 Inspect bearings on output and pinion shafts To replace press new bearing on to shaft NOTE Due to ext...

Page 200: ...t cover NOTE Be sure backlash plate in in place E D Backlash Plate 8 Install the retaining ring F into the output cover Be sure the retaining ring is properly seated into the cover F 9 Install the rin...

Page 201: ...19 Nm 13 Install new seals into the gearcase housing and gearcase housing cover Back Lash Pad Thrust Pad Adjustment 14 Lay the gearcase on the side with the output cover facing up 15 The backlash scr...

Page 202: ...two distinct wear bands one band inside the other If only one band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 4 A band with an interrupted...

Page 203: ...rs FRONT HOUSING INSTALLATION 1 To install gearcase reverse removal procedure Use new spring pin in front prop shaft 2 Torque mounting bolts to 30 ft lbs 41 Nm 30 ft lbs 41 Nm New Roller Pin 3 Add the...

Page 204: ...6 1 Bushing 7 1 Hub Race Output Male 27 1 Gearcase LH 8 1 Pin Dowel 28 2 Seal Oil 9 1 Dowel 29 1 Plug Oil Fill 10 1 Clutch Housing Ring Gear 30 4 N A 11 1 Spring 31 4 N A 12 14 Kit Roll 32 1 Plug Oil...

Page 205: ...n the wheel nuts 5 Safely support the rear of the ATV CAUTION Secure the machine Serious injury could occur if machine tips or falls 6 Remove wheel nuts and wheel 7 Remove the rear brake caliper and s...

Page 206: ...5 ft lbs 48 Nm 3 Install and torque both lower control arm bolts 4 Lift bearing carrier until top aligns with upper control arm Install and torque upper control arm bolt and torque to specification Re...

Page 207: ...y close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoo...

Page 208: ...ll snap ring into groove REAR DRIVE SHAFT REMOVAL 1 Remove rear hub and bearing carrier See Pages 7 19 2 Tip hub outward and remove shaft from hub 3 Pull sharply outward to remove shaft from transmiss...

Page 209: ...ension components S Never use a hammer or sharp tools to remove or to install boot clamps S Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joi...

Page 210: ...nner hub to locate snap ring Snap ring located in recessed area Snap ring 3 Open the snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft with a soft faced hammer wh...

Page 211: ...oot clamp using boot clamp pliers Open snap ring and pull CV joint away from shaft Boot Replacement 1 Remove CV joint from end of shaft 2 Remove boot from shaft NOTE When replacing a damaged boot chec...

Page 212: ...t is in its correct location on the axle CARE MUST BE TAKEN TO AVOID DAMAGE TO THE NEWLY INSTALLED BOOT 9 Install the small clamp on the boot 10 Be sure to use only the Constant Velocity Joint grease...

Page 213: ...g gear for abnormal wear broken or chipped teeth Spin the bearing to check the ball bearings for smoothness Replace the bearing if needed 6 Remove the input shaft cover and the pinion shaft from the g...

Page 214: ...rings seals and worn components 3 Install the pinion shaft into the gearcase housing Install the pinion shaft cover and torque the cover bolts to 25 ft lbs 34 Nm Pinion Shaft Cover Bolt Torque 25 ft...

Page 215: ...ss pattern Gearcase Cover Bolt Torque 25 ft lbs 34 Nm 6 Install the drain plug and fill plug Replace the drain plug washers to ensure proper sealing after filling Drain Plug 14 18 ft lbs 19 24 Nm REAR...

Page 216: ...1 Cover Output LH 12 1 Ball Bearing 2 8 Screw 13 1 O ring 3 1 Tube Vent 14 1 Cover Input 4 2 Washer 15 1 Seall 5 2 Plug 16 1 Rear Gearcase Housing 6 2 Bearing Roller Ball 17 2 Ball Bearing 7 AR Shim 1...

Page 217: ...ion Exploded View 8 2 8 3 Torque Specifications Lubrication 8 4 Gear Shift Selector Removal 8 4 Transmission Removal 8 4 8 5 Transmission Installation 8 5 8 6 Transmission Disassembly 8 6 8 11 Transmi...

Page 218: ...bolt threads Apply Polaris Crankcase Sealant 262 FOR REASSEMBLY TORQUE SPECIFICATIONS Item 1 3 23 33 39 70 71 Torque 12 18 fl lbs 16 24 Nm 7 9 ft lbs 9 5 12 Nm 15 19 ft lbs 20 26 Nm 27 34 ft lbs 37 46...

Page 219: ...e Bearing 14 1 Vent Tube 49 1 24T 6 Face Sprocket 15 1 O ring 50 1 Washer 16 1 Shift Drum 51 2 External Retaining Ring 17 1 External Retaining Ring 52 4 6 Face Engagement Dog 18 1 6 Pin Switch 53 2 Wa...

Page 220: ...t type and capacity GEAR SELECTOR REMOVAL 1 Disconnect linkage rod from gear selector handle 2 Remove two bolts attaching gear selector mount to machine frame 3 Lift gear selector out of mounting brac...

Page 221: ...rk lock spring Park Lock Spring 11 Remove left side transmission bracket rear bracket and lower right bracket bolt 12 Remove front transmission to engine mount bolts See illustration 13 Remove transmi...

Page 222: ...k Cover Shift Shaft Detent Pawl Case 2 Remove the nut and washer that secure the bell crank Remove the bellcrank 3 Remove the e clip and then remove the transmission switch Transmission Switch 4 Remov...

Page 223: ...place a mark just above the keyed spline Note the raised edge on the detent gear for reassembly 7 Remove the shift shaft and detent lever 8 Note the timing marks on the shift gears Remove the shift g...

Page 224: ...each fork 12 Remove the bearing from the reverse shaft using a puller 13 Remove the park lock engagement dog Remove the wave spring and reverse engagement dog Engagement Dogs 14 Remove the bearing fro...

Page 225: ...rest of the bearings from the shafts 19 Use a press to remove the gear from the shaft 20 Make note of the direction of the gear and hub location 21 Remove the gear split bearing and washer from the re...

Page 226: ...TRANSMISSION 8 10 24 Remove bearing and the helical gear 25 Remove the pinion shaft retainer plate and the pinion shaft 26 Remove the front housing cover screws...

Page 227: ...gears and replace if edges are rounded 32 Inspect gear teeth for wear cracks chips or broken teeth Note the location of the hubs on the gear 33 Remove seals from transmission case IMPORTANT New seals...

Page 228: ...place Front Cover Bolt Torque 27 34 ft lbs 36 50 46 Nm 5 Install new front and rear output shaft seals Apply grease to the seal lips Cover the splines of the shaft to protect the seal lips during inst...

Page 229: ...12 Install the engagement dogs wave springs and bearing 13 Install the ball bearing onto the end of the input shaft 14 As the engagement dogs are installed onto the shaft place the wave springs into t...

Page 230: ...e pocket on the backside of the case 20 Install the helical gear and bearing onto the pinion shaft 21 Clean the mating surfaces of the case and cover Apply Crankcase Sealant PN 2871557 to the mating s...

Page 231: ...on the end of the shaft Keyed Spline Detent Star 27 Install the detent pawl and spring Install a new o ring onto the shift shaft after the detent pawl is assembled to the shaft Place a small amount of...

Page 232: ...lcrank nut to 12 18 ft lbs 16 24 Nm Bellcrank Nut Torque 12 18 ft lbs 16 24 Nm 33 Install the shift switch Install the retaining clip Hook up the switch harness and reconnect the lockout plunger sprin...

Page 233: ...r Removal 9 9 Master Cylinder Installation 9 9 9 10 Front Pad Removal 9 10 9 11 Front Pad Assembly 9 12 9 13 Brake Burnishing 9 13 Front Disc Inspection 9 13 Front Disc Removal Replacement 9 13 9 14 F...

Page 234: ...Disc Thickness 150 165 3 81 4 19mm 140 3 56mm Brake Disc Thickness Variance Between Measurements 002 051mm Brake Disc Runout 010 254mm Master Cylinder I D Front 750 Master Cylinder I D Aux Rear 500 TO...

Page 235: ...IN COMPONENTS All Banjo Style Fittings 15 ft lbs 21Nm 1 All Bleed Screws 25 30 in lbs 2 80 3 40 Nm All Flare Style Fittings 12 15 ft lbs 16 21Nm 2 3 2 Screws 5 in lbs 0 56 Nm 2 2 2 2 3 3 3 1 1 1 1 App...

Page 236: ...ft lbs 41 48 Nm Piston Bushings Seal Bracket Pads Front Housing Anvil O ring FLUID TO COMPONENT 3 3 3 APPLY POLARIS DOT 3 BRAKE FRONT BRAKE CALIPER EXPLODED VIEW Caliper Mount Piston Bushing Boot Squ...

Page 237: ...after pad service S Check and adjust master cylinder reservoir fluid level after pad service S Make sure atmospheric vent on reservoir is unobstructed S Test for brake drag after any brake system serv...

Page 238: ...ter cylinder Move able Brake Pad G Typical Hydraulic Brake System The Polaris disc brake system consists of the following components or assemblies brake lever master cylinder hydraulic hose brake cali...

Page 239: ...le piston conventional design The rear caliper piston is a T shaped which allows both hand and foot brake to use the same caliper piston but remain separated by seals The hand brake system applies hyd...

Page 240: ...cover See Illustration above 7 Slowly pump brake lever D until pressure builds and holds 8 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever NOTE Do not r...

Page 241: ...to come in contact with finished surfaces 3 Remove master cylinder from handlebars 4 Hold brake upright and continue to remove master cylinder Cover brake line to avoid spillage MASTER CYLINDER INSTAL...

Page 242: ...Polaris DOT 3 Brake Fluid PN 2870990 4 Follow bleeding procedure on Pages 9 7 9 8 Check all connections for leaks and repair if necessary FRONT PAD REMOVAL 1 Elevate and support front of machine CAUT...

Page 243: ...hed back into caliper Remove excess fluid from reservoir as required 5 Push mounting bracket inward and slip outer brake pad past edge Remove inner pad 6 Measure the thickness of the pad material Repl...

Page 244: ...se the pads use only new clean pads 3 Install caliper on hub strut and torque mounting bolts 18 ft lbs 25 Nm Front Caliper Mounting Bolts Torque 18 ft lbs 24Nm 4 Slowly pump the brake lever until pres...

Page 245: ...orn beyond service limit Brake Disc Thickness Service Limit 140 3 556 mm New 150 165 3 810 4 19 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements 3 Mount dial i...

Page 246: ...line wrench loosen and remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 2 Remove the brake caliper mounting bolts 3 Remove brake caliper and drain f...

Page 247: ...hes wear or damage Measure diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined for brake pad replacement this section See Pages 9 10 9 11 FRONT C...

Page 248: ...torque mounting bolts 18 ft lbs 24 Nm 15 ft lbs 21 Nm Front Caliper Mounting Bolt 18 ft lbs 24 Nm Torque Specifications Front Banjo Bolt Brake Line 15 ft lbs 21 Nm 2 Install brake line and tighten sec...

Page 249: ...e slide bolt Clip 3 Loosen one of the slide pins with a hex wrench 4 Remove caliper mounting bolts and lift caliper off of disc NOTE When removing caliper be careful not to damage brake line Support c...

Page 250: ...aliper 18 ft lbs 24 Nm Torque Specifications Caliper Slide Pin Torque 30 35 ft lbs 41 Nm 48 Nm 4 Install the slide bolt snap ring Torque the slide pin to 30 35 ft lbs 41 Nm 48 Nm 30 35 ft lbs 41 48 Nm...

Page 251: ...cket pad C and the brake pads D A Caliper B C D 5 Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers Seal Piston O rings Caliper Anvil Bolts 6 Remove seals and O...

Page 252: ...fluid to piston seals and install carefully with a twisting motion to ease assembly until fully seated O Rings Seals 2 Carefully assemble caliper body making sure O rings are properly positioned in g...

Page 253: ...g into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when lever is released If the brake drags re check assembly and installation REAR BRAKE DISC INSPECTION 1 Vis...

Page 254: ...tch the brake fluid Dispose of brake fluid properly 2 Remove the two bolts that secure the rear master cylinder to the brake mount plate Replace parts as needed 3 To install the rear brake master cyli...

Page 255: ...ed lever G Incorrectly adjusted stationary pad G Worn or damaged master cylinder or components G Improper clearance between lever and switch Lever Vibration G Disc damaged G Disc worn runout or thickn...

Page 256: ...BRAKES 9 24 NOTES...

Page 257: ...ttle Circuit System Operation 10 17 Flywheel Identification 10 18 Ignition System Operation 10 18 Ignition System Component Identification 10 19 Ignition System Testing Flow Chart 10 20 Ignition Syste...

Page 258: ...r Coil Gap 022 028 inch 56 71 mm GEAR POSITION INDICATOR SWITCH TEST High Range Neutral Reverse F F F Low Range C B A D High Low Neutral Reverse Park Switch A B C D E F TRANSMISSION SWITCH E F F F F P...

Page 259: ...istor If the engine temperature continues to rise it will turn on an engine hot indicator The module also contains provisions for detecting an open thermistor An open thermistor will cause the engine...

Page 260: ...ment cluster Brown C and H GND Battery Negative Blue White D HOT_LAMP Engine hot signal Provides a ground path for a lamp Red E and F BAT Positive side of battery Both pins should be used to carry cur...

Page 261: ...the odometer displays without a decimal point Hour Meter logs the total hours the engine has been in operation 2 Programmable Service Interval Diagnostic Mode Service Interval The purpose of the prog...

Page 262: ...h on 4 Release the switch as soon as the display is activated Use the mode reverse override button to toggle through the diagnostic screens NOTE The initial screen display refers to the software versi...

Page 263: ...e the button is pressed Pressing and holding the buttonwill allow the numbers to escalate much faster 3 When the desired time increment is displayed release the button and wait for the wrench to stop...

Page 264: ...When the display stops flashing the mode has been set MP Miles Km Kilometers NOTE As long as you are in the diagnostic mode the wrench icon will remain lit NOTE To leave the diagnostic mode turn the...

Page 265: ...lled and that the indexing key is in the headlight pod keyway Align Index Points 3 Hold the pod assembly securely and insert the instrument cluster into the pod assembly Twist the instrument cluster g...

Page 266: ...M CLUSTER CHECK FOR 12V FROM BRN WHITE TO GROUND Y Y SWITCH ON RECONNECT CLUSTER LEAVE HEADLIGHT POD DISASSEMBLED SHIFT TO LOW OR HIGH LEAVE AWD ON Y Y REPLACE INSTRUMENT CLUSTER PROCEED TO IF AWD PRO...

Page 267: ...ll 5 Green 6 Blue 7 Yellow Red RPM Input 8 Brown Ground 9 Blue White Engine Overheat Switch 10 N C 11 N C 12 Purple White Reverse Gear 13 Green White Neutral 14 White 15 N C 16 Brown White AWD Control...

Page 268: ...E AWD ICON ON MECHANICAL PROBLEM N INSPECT HUB COIL WIRING FOR SHORT CIRCUITS TO GROUND DISCONNECT CONNECTOR MEASURE BETWEEN HUB COIL BROWN WHT GROUND REPAIR HUB COIL WIRING REPLACE SPEEDOMETER NO PRO...

Page 269: ...levate front right side of vehicle until tire is off the ground 4 Slowly turn right front wheel while observing the test light 5 If light flashes sensor is O K Be sure connections are good and 9 volt...

Page 270: ...ch position the Instrument cluster interprets the resistance reading and displays the corre sponding shift position in the LCD panel Testing Use the diagram provided to test the continuity loop at eac...

Page 271: ...N Above 50k Open Thermistor Replace Thermis tor Hot light ON Below 178 Engine Overheat or Bad Thermistor THERMISTOR READING DURING OPERATION Condition Approx Reading Min Max Temperature Hot Light On 1...

Page 272: ...or cooling system information FAN CONTROL CIRCUIT OPERATION TESTING The fan is controlled through the ECM and thermistor Refer to Engine Temperature Controller on Page 10 5 for fan operation informati...

Page 273: ...r NOTE Adjust throttle cable freeplay ETC switch and make sure throttle mechanism is functioning properly before testing the switch Refer to Maintenance Chapter 2 for cable adjustment procedure ETC OP...

Page 274: ...starts G Simpler component design for ease trouble shooting and maintenance Operation Overview The DC CDI system relies on battery power for ignition Instead of generating DC voltage via magnetic indu...

Page 275: ...the same but have different internal circuitry Be sure to always use the correct part number Stator Assembly Battery Flywheel Starter Solenoid Negative Battery Cable Winch Harness Ignition Controller...

Page 276: ...n ohmmeter The coil mount should have good continuity to ground on the engine 0 2 Replace Spark Plug Disconnect and check the secondary coil Resis tance values should be Primary Side Primary Wire Tab...

Page 277: ...DI module wire connector from ignition coil primary side A Connect one meter lead to Black wire ground and the other to the White wire both wires come from the CDI module Crank engine and check output...

Page 278: ...uce the chance of damage to electrical components The break even point of the charging system is the point at which the alternator overcomes all system loads lights etc and begins to charge the batter...

Page 279: ...lue of each of the stator legs to ground Y1 to Ground Y2 to Ground Y3 to Ground See table in Test 1 NOTE Any measurement other than Infinity open will indicate a failed or shorted stator leg TEST 3 Me...

Page 280: ...be present on red wire terminal on harness side of voltage regulator connector Is it Check regulator rectifier connections and ground battery connections cir cuit breaker and connecting wires Repair...

Page 281: ...ilate when charging or using in an enclosed space Always shield eyes when working near batter ies KEEP OUT OF REACH OF CHILDREN WARNING The gases given off by a battery are explosive Any spark or open...

Page 282: ...rfill the battery Refill using only distilled water Tap water contains minerals which are harmful to a battery Do not allow cleaning solution or tap water inside the battery Battery life may be reduce...

Page 283: ...aled Type 100 Charged 75 Charged 50 Charged 25 Charged 0 Charged 12 60V 12 40V 12 10V 11 90V less than 11 80V 12 70V 12 50V 12 20V 12 0V less than 11 9V SPECIFIC GRAVITY State of charge Conventional l...

Page 284: ...fic gravity to 1 270 or greater 3 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with a corrosion resistant dielectric grease Dielectric Grease PN 2871...

Page 285: ...intenance battery Doing so will damage the case and shorten the life of the battery Refer to the Battery Maintenance Video PN 9917987 for proper instruction on servicing Low Maintenance batteries To s...

Page 286: ...y should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test LOW MAINTENANCE BATTERY OCV OPEN CIRCU...

Page 287: ...corrosion from the cables and terminals G Make sure that the electrolyte is at the proper level G Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specif...

Page 288: ...urn the headlight lamp socket counter clockwise and remove Loosen Tighten Turn Harness Assembly 5 Carefully remove headlamp bulb from housing 6 Remove the headlamp and replace with a new headlamp NOTE...

Page 289: ...Sides D 5 Pull the headlight housing up to release from the locking tabs Both Sides 6 Lift the adjusting knob up to remove from the locking tabs 7 Carefully pull the assembly up and out of pod 8 Reve...

Page 290: ...uld be aimed 2 5 1 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be included on the seat On machines with separate low beam lights the drop should be 8 20 3 cm in 25 from the c...

Page 291: ...2871329 3 Reinstall the lens cover removed in Step 1 4 Test the tail light brake light to see it is working BRAKE LIGHT SWITCH 1 Remove the front cover Brake Lamp Switch Brake Switch Location Under f...

Page 292: ...on a flat surface 3 Hook up an ohm meter to the fuel sender harness Brown Purple White 4 With the sender float in the empty position the meter should read 5 ohms 5 Slowly lift the sender float to the...

Page 293: ...Solenoid Removal WARN WINCH SWITCH INSTALLATION 1 Remove the front A and rear B bolts from the master cylinder clamp Be careful not to lose the spacers C 2 Rotate the winch mini rocker switch upward...

Page 294: ...20 ga Green Black Black 6 ga Cable Boot Blue Cable 6 ga Yellow Cable 6 ga 12V Contact Red Cable 6 ga Rocker Switch IN OUT Fairlead Roller Strap Clevis Battery NOTE See the wiring diagram in back of th...

Page 295: ...TEST The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a...

Page 296: ...infinite OL Inspect insulation on brush wires for damage and repair or replace as necessary 3 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide br...

Page 297: ...opriate solvent If the commutator needs cleaning use only electrical contact cleaner ARMATURE TESTING 1 Remove armature from starter casing Note order of shims on drive end for reassembly 2 Inspect su...

Page 298: ...ile holding brush springs away from brushes push brushes back and hold in place 4 Slide armature into field magnet housing Release brushes 5 Lightly grease the drive roller bearing and reinstall drive...

Page 299: ...ing Gear Assembly Thrust Washer Bushing Spring Thrust Washer Retaining Ring Stopper Cover Polaris Premium Starter Drive Grease PN 2871460 1 Screw the overrun clutch out to the engaged position on the...

Page 300: ...cription Ref 1 Rubber Ring 10 Gear Assembly 2 Brush Spring 11 Though Bolt 3 Thrust Washer 12 Cover 4 Gear Assembly 13 Stopper 5 O Ring 14 Snap Ring 6 Brush Complete 15 Washer 7 O Ring 16 Flange Bolt 8...

Page 301: ...olenoid Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery to solenoid wire De press starter button Reading should be less than 1 V D C Clean the...

Page 302: ...ELECTRICAL 10 46 NOTES...

Page 303: ...ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN MV7 CIVILIAN VERSION...

Page 304: ...ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN MV7 CIVILIAN VERSION...

Page 305: ...Replacement Front 9 13 Brake Fluid Level 2 31 Brake Hose Fitting Inspection 2 33 Brake Light Switch Testing 10 35 Brake Master Cylinder Exploded View Rear 9 5 9 22 Brake Noise 9 5 Brake Pad Assembly...

Page 306: ...isassembly 6 11 6 12 6 13 Drive Clutch Exploded View 6 2 Drive Clutch Inspection 6 11 Drive Clutch Operation 6 3 Drive Shaft Boot Inspection 7 3 Drive Shaft Boot Replacement 7 4 Driven Clutch Assembly...

Page 307: ...nt 5 22 Fuel Filter Maintenance 2 18 Fuel Pump Service 4 13 Fuel Sender Removal 4 14 Fuel Sender Test 10 36 Fuel Stabilizer 2 38 Fuel System 2 17 Fuel Tank Assembly Exploded View 4 3 G Gear Circuit Re...

Page 308: ...Inspection 2 10 Progammable Service Interval Diagnostic Mode 10 5 Publication Numbers 1 3 Push Rod Inspection 3 19 PVT Assembly 6 8 PVT Cover Removal Install 6 6 PVT Disassembly 6 7 PVT Drying 2 26 6...

Page 309: ...Front Inspection 2 34 Suspension Rear Inspection 2 34 T Taillight Lamp Replacement 10 35 Tap Drill Chart 1 13 Throttle Cable Adjustment 2 16 Throttle Operation 2 14 Tie Rod Inspection 2 28 Tire Inspe...

Page 310: ...e ATV 2 38 Water Oil Pump Removal 3 42 Wheel Inspection 2 35 Wheel Installation 2 35 Wheel Removal Front or Rear 2 35 Wheel Hub Spindle Torque 2 35 Winch Removal Install 5 10 Winch Switch Installation...

Page 311: ...____Zip _________________ Publication Title Part Number ____________________________ Page s ____________ Comments Name ______________________________________________________________________ Address __...

Page 312: ...2005 SPORTSMAN MV7 SERVICE MANUAL PN 9919963 2005 SPORTSMAN MV 7 SERVICE MANUAL PN 9919963 Printed in USA 9919963 PART Cvr_9919963 10 19 04 2 43 PM Page 1...

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