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Polaris 2006 HAWKEYE 2x4, Repair Manual

The Polaris 2006 HAWKEYE 2x4 Repair Manual is a comprehensive guide for all your maintenance and repair needs. This manual provides detailed instructions and diagrams to ensure hassle-free troubleshooting and repairs. Download this essential manual for free from manualshive.com and keep your HAWKEYE running smoothly.

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6.6

BODY AND STEERING

Operation Overview

The Polaris disc brake system consists of the following 
components or assemblies:  hand brake lever; foot brake lever, 
hand and foot brake master cylinders; hydraulic hoses; brake 
calipers (slave cylinders); brake pads; and brake discs, which 
are secured to the drivetrain.

When the hand activated brake lever (A) is applied it contacts 
piston (B) within the master cylinder.  As the master cylinder 
piston moves inward it closes a small opening (compensating 
port C) within the cylinder and starts to build pressure within 
the brake system.  As the pressure within the system is 
increased, the piston (D) located in the brake caliper moves 
outward and applies pressure to the brake pad.  This pad 
contacts the brake disc and moves the caliper in its floating 
bracket, pulling the stationary side pad into the brake disc.  
The resulting friction reduces brake disc and vehicle speed.  
As the lever pressure is increased, the braking affect is also 
increased.

The friction applied to the brake pads will cause the pads to 
wear.  As these pads wear, the piston within the caliper moves 
further outward and becomes self adjusting.  Fluid from the 
reservoir fills the additional area created when the caliper 
piston moves outward.

Brake fluid level is critical to proper system operation.  Too 
little fluid will allow air to enter the system and cause the 
brakes to feel spongy.  Too much fluid could cause brakes to 
drag due to fluid expansion.

Located within the master cylinder is the compensating port 
(C) which is opened and closed by the master cylinder piston 
assembly.  The port is open when the lever is released and the 
master cylinder piston is outward.  As the temperature within 
the hydraulic system changes, this port compensates for fluid 
expansion (heated fluid) or contraction (cooled fluid).  During 
system service, be sure this port is open.  Due to the high 
temperatures created within the system during heavy braking, 
it is very important that the master cylinder reservoir have 
adequate space to allow for fluid expansion.  

Never overfill 

the reservoir!

  Fill to 1/4, - 5/16, (.64 - .80 cm) from top of 

the cylinder.

This system also incorporates a diaphragm (E) as part of the 
cover gasket; and a vent port (F) located between the gasket 
and the cover.  The combination diaphragm and vent allow for 
the air above the fluid to equalize pressure as the fluid 
expands or contracts.  Make sure the vent is open and allowed 
to function.  If the reservoir is over filled or the diaphragm 
vent is plugged the expanding fluid may build pressure in the 
brake system leading to brake fail

When servicing Polaris ATV brake systems, use only DOT 3 
or DOT 4 Brake Fluid.

A

B

C

D

E

F

Must be clear to 
allow proper 
diaphragm 
movement

Compensating port 
compensates for 
temperature changes by 
allowing fluid back to 
master cylinder

Move Brake Pad

WARNING

Once a bottle is opened, use what is necessary and dis-

card the rest in accordance with local laws.  Do not store 

or use a partial bottle of brake fluid.  Brake fluid is hy-

groscopic, meaning it rapidly absorbs moisture.  This 

causes the boiling temperature of the brake fluid to drop, 
which can lead to brake fade and the possible loss of con-

trol.

Summary of Contents for 2006 HAWKEYE 2x4

Page 1: ...ERIAL NUMBER LOCATIONS 1 2 SPECIFICATIONS 1 3 MODEL 2006 HAWKEYE 2X4 1 3 MODEL 2006 HAWKEYE 4X4 1 3 MODEL 2006 HAWKEYE 2X4 1 4 MODEL 2006 HAWKEYE 4X4 1 5 GENERAL INFORMATION 1 6 PUBLICATION NUMBERS 1 6 REPLACEMENT KEYS 1 6 SPECIAL TOOLS 1 7 STANDARD TORQUE SPECIFICATIONS 1 9 SAE TAP DRILL SIZES 1 10 METRIC TAP DRILL SIZES 1 10 DECIMAL EQUIVALENTS 1 10 CONVERSION TABLE 1 11 GLOSSARY OF TERMS 1 12 ...

Page 2: ... the recoil housing on the right side of engine A An additional number is stamped on the center top of crankcase beneath the cylinder coolant elbow The machine serial number 1 lower frame rail and engine number 2 right side engine are important for vehicle identification Machine Model Number Identification Year Designation Basic Chassis Designation Engine Designation Emissions Model Option A 0 6 L...

Page 3: ... Weight 930 lbs 422 kg Front Rack Capacity 70 lbs 31 75 kg Rear Rack Capacity 100 lbs 45 kg Towing Capacity 750 lbs 340 kg Hitch Tongue Weight 75 lbs 34 kg Body Style Recreational Utility Category Dimension Length 74 in 188 cm Width 42 in 107 cm Height 45 5 in 116 cm Wheel Base 46 in 117 cm Ground Clearance 8 in 20 3 cm Dry Weight 550 lbs 250 kg Gross Vehicle Weight 930 lbs 422 kg Front Rack Capac...

Page 4: ...ystem DC CDI Ignition Timing BTDC 30 2deg 5000 RPM Spark plug Gap NGK CR8E 031 in 8 mm Battery Model Amp Hr Conventional 14 Amp hr Circuit Breakers Fusible Link 15 amp Main 15 Amp Accsy Starting Electric Recoil Back up Indicator Panel LCD Indicator lights Drivetrain Transmission Type H N R Transmission Capacity 15 2 oz 450 ml Gear Ratio Foward Reverse 15 18 1 14 05 1 Clutch Type CVT w EBS Belt 321...

Page 5: ...n Timing BTDC 30 2deg 5000 RPM Spark plug Gap NGK CR8E 031 in 8 mm Battery Model Amp Hr Conventional 14 Amp hr Circuit Breakers Fusible Link 15 amp Main 15 Amp Accsy Starting Electric Recoil Back up Indicator Panel LCD Indicator lights Drivetrain Transmission Type H N R Transmission Capacity 15 2 oz 450 ml Gear Ratio Front Output Rear Output Fwd 5 17 1 Rev 4 79 1 Fwd 15 18 1 Rev 14 05 1 Clutch Typ...

Page 6: ...tify which series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number Should both keys become lost replacement of the ignition switch assembly is necessary Year Model Model No Owner sManual PN Parts Manual PN Parts Micro Fiche PN 2006 Hawkeye 2x4 A06LB27AA 9920202 9920207 9920208 2006 Hawkeye 4x4 A06LD27AB AC 9920202 9920207 99202...

Page 7: ... servicing any Polaris product Standard Tools and Engine Tools 2871293 B Crankshaft Slotted Nut Socket PA 47344 Balance Shaft Slotted Nut Socket 2870975 Mity VacTM 2870773 C Clip Install Tool 2870390 Piston Support Block PA 47478 Drive Clutch Holder Standard Tools and Engine Tools 2870569 Crankshaft True Kit PV 35667 A Cylinder Leakdown Tester PU 45432 Caliper or A Basic Caliper Suspension Tools 2...

Page 8: ...3 Hone Kit 2870305 Stone Replacement Kit 2870588 Hone Oil 12 OZ 2200634 Valve Seat Reconditioning Kit 2870459 Dial Indicator Electrical Tools PV 43568 FlukeTM 77 Multimeter PV 39617 Current Clamp 2870836 Battery Hydrometer 8712500 PV 39951 A Tachometer Tachometer ...

Page 9: ...e sections Bolt Size Threads In Grade 2 Grade 5 Grade 8 Torque in lbs Nm 10 24 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 35 48 50 69 7 16 14 30 40 50 69 70 97 7 16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 ...

Page 10: ... mm 9449 61 64 9531 31 32 9688 25 mm 9843 63 64 9844 1 1 0 Thread Size Drill Size Thread Size Drill Size 0 80 3 64 1 2 13 27 64 1 64 53 1 2 20 29 64 1 72 53 9 16 12 31 64 2 56 51 9 16 18 33 64 2 64 50 5 8 11 17 32 3 48 5 64 5 8 18 37 64 3 56 45 3 4 10 21 32 4 40 43 3 4 16 11 16 4 48 42 7 8 9 49 64 5 40 38 7 8 14 13 16 5 44 37 1 8 7 8 6 32 36 1 12 59 64 6 40 33 1 1 8 7 63 64 8 32 29 1 1 8 12 1 3 64...

Page 11: ...nches cu in x 16 387 Cubic centimeters cc Cubic 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 qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 Liters l Liters l x 1 057 US quarts ...

Page 12: ...e pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm2 Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction l or ltr Liter lbs ...

Page 13: ... 14 FUEL LINES 2 14 VENT LINES 2 14 FUEL FILTER 2 14 COMPRESSION TEST 2 15 ENGINE MOUNTS 2 15 ENGINE FASTENER TORQUE 2 15 BATTERY MAINTENANCE 2 15 SPARK PLUG 2 16 IGNITION TIMING 2 17 MAIN AIR FILTER CLEANING 2 17 AIR FILTER PRE FILTER SERVICE 2 17 AIR BOX SEDIMENT TUBE 2 18 CVT DRAIN PLUG DRYING 2 18 ENGINE OIL LEVEL 2 18 OIL AND FILTER CHANGE 2 19 VALVE CLEARANCE ADJUSTMENT 2 20 STEERING 2 20 TI...

Page 14: ...he oil 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 to be aware of during maintenance CAUTION Due to the nature of these adjustments it is recommended this service be performed by an authorized Polaris dealer SEVERE USE ITEM If vehicle is subjected...

Page 15: ... Air box sediment tube Daily Drain deposits when visible Coolant if applicable Daily Check level daily change coolant every 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed Recoil housing if equipped Weekly Drain water as needed check often if operating in wet conditions Brake pad wear 10 H Monthly 100 ...

Page 16: ...necessary E Choke cable 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50 H 6 M 500 800 Inspect ducts for proper sealing air leaks Drive belt 100 H 12 M 1000 1600 Inspect adjust replace as needed Cooling system if applicable 50 H 6 M 500 800 Inspect coolant strength seasonally pressure test system yearly E Engine oil change Severe Duty Normal Du...

Page 17: ...gnition Timing 100 H 12M 1000 1600 Inspect Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Clutches drive and driven 100 H 12M 1000 1600 Inspect clean replace worn parts Front wheel bearings 100 H 12M 1000 1600 Inspect replace as needed Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrestor 300 H 36M 3000 ...

Page 18: ...MAINTENANCE 2 6 LUBRICANTS FLUIDS POLARIS LUBES FLUIDS ATV Angle Drive Fluid 0W 40 2874865 Quarts 2874867 55 Gallon Drum ...

Page 19: ...remium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogel Part No Description Additives Sealants Thread Locking Agents Misc 2870585 Loctite Primer N Aerosol 25 g 2871956 Loctite Thread Sealant 565 50 ml 6 Count 2871949 Loctite Threadlock 242 50 ml 10 Count 2871950 Loctite Threadlock 242 6 ml 12 Count 2871951 Loct...

Page 20: ...cludes auxiliary brake Throttle check for free operation Headlight Taillight Brakelight check operation of all indicator lights and switches Engine stop switch check for proper function Wheels check for loose wheel nuts Air cleaner element check for dirt or water clean or replace Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for any...

Page 21: ...il to proper level Change after 1st month 25 hours 50 hours thereafter Change more often 25 hours in severe duty conditions or short trip cold weather operation 2 Transmission Polaris AGL Lubricant See procedure Change annually2 3 Brake Fluid Polaris DOT 3 Brake Fluid Fill master cylinder reservoir to indicated level inside reservoir As required Change fluid every 2 years 4 Rear Gearcase Polaris A...

Page 22: ...efer to Page 2 6 2 8 for the Polaris Lubricant Identification table 2 Transmission Oil 4 Rear Gearcase Oil 5 Bottom Rear Lower Control Arm 3 Brake Fluid 1 Engine Oil Reservoir Level Lower Rear Bearing Carrier Pivot Prop Shaft ...

Page 23: ...tenance schedule Be sure vehicle is level before proceeding Check vent hose to be sure it is routed properly and unobstructed Oil Level Check 1 Position the vehicle on a level surface 2 Remove the check fill plug A and view the oil level The oil level should be at the bottom of the check plug B threads 3 Reinstall the check fill plug A Torque to specification 4 Reinstall the check plug A and a new...

Page 24: ...he turning range inspect throttle cable routing and condition If cable is routed properly and in good condition repeat adjustment procedure 5 Replace the throttle cable if worn kinked or damaged CHOKE ENRICHER ADJUSTMENT Verify free play of 1 16 3 16 1 6 4 76 mm and smooth operation of choke cable Adjustments to the freeplay can be made by loosening the choke cable adjustment in or out to gain the...

Page 25: ...r the PET 2500 PN 8712500 4 Set idle speed to 1200 RPM Always check throttle cable freeplay after adjusting idle speed and adjust if necessary 5 Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss CAUTION The pilot screw is calibrated at the factory to meet EPA CARB regulations for air quality standards and is sealed with a brass plug to prevent tamper ing ...

Page 26: ... tank neck If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time Never drain the float bowl wh...

Page 27: ...pected shelf life is 6 8 months depending on storage conditions As a general rule before placing the battery into service check the battery condition and charge accordingly Low Maintenance batteries are permanently sealed at the time of manufacture The use of lead calcium and AGM technology instead of lead antimony allows the battery acid to be fully absorbed For this reason a Low Maintenance batt...

Page 28: ...to engine when plug is removed 3 Remove spark plug 4 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 5 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 6 Measure gap with a wire gauge Refer to specifications for proper spark plug type and ...

Page 29: ...equired more often The pre filter should be cleaned before each ride using the following procedure 1 Remove the seat 2 Remove clips from air box cover A and remove cover 3 Inspect the gasket It should adhere tightly to the cover and seal all the way around 4 Remove air filter assembly Cleaning 5 Slip the pre filter element off of main element Clean the pre filter with hot soapy water 6 Rinse and d...

Page 30: ... ATV should be checked immediately 1 To release any water that maybe trapped in the CVT cover simply remove the CVT drain plug and O ring located on the bottom of the CVT cover and let the water drain out 2 To further expel water from the cover and to dry out the CVT system shift the transmission to neutral and rev engine slightly to expel the moisture and air dry the belt and clutches Allow engin...

Page 31: ...tart the engine Allow it to idle for two to three minuets 5 Turn the engine off 6 Clean the area around the drain plug 7 Place a drain pan under the vehicle 8 Remove the drain plug Use a 6mm Allen wrench 9 Drain the oil 10 Reinstall the drain plug with a new sealing washer 11 Torque to 14 ft lb 19Nm NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks o...

Page 32: ... screw 3 When clearance is correct hold adjuster screw and tighten locknut securely 4 Re check the valve clearance 5 Repeat adjustment procedure if necessary until clearance is correct with locknut secured EXHAUST VALVE CLEARANCE 1 Verify cam lobes are pointed down 2 Insert an 006 15 mm feeler gauge between end of exhaust valve stem and adjuster screw 3 Loosen locknut and turn adjuster screw until...

Page 33: ...ace machine on a smooth level surface 2 Set handlebars in a straight ahead position and secure handlebars in this position NOTE The steering arm can be used as an indicator of whether the handlebars are straight The arm should always point straight back from the steering post 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub a...

Page 34: ...Remove the fastener 1 and remove the arrestor from the CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned in correctly it will not pivot and may break Measurement B Chalk Line Measurement A WARNING Do not perform clean out immediately after the engine has been run as the exhaust system bec...

Page 35: ...ance schedule and before each ride Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir Check the fluid level eye If it is clear it is an indication that fluid is needed or the brake pads may be worn which can reduce the fluid level Use Polaris DOT 3 or DOT 4 Brake Fluid Check brake system for fluid leaks excessive travel or spongy feel Check brake pads for wea...

Page 36: ... 4mm 5 If more than one inch two things must be examined Free play of the brake pedal should be 1 8 1 4 inch 3 2 6 35 mm If free play is excessive Inspect brake pads pedal linkage springs and hoses for wear or damage and replace any parts as needed SUSPENSION SPRING FRONT REAR PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspension spring preload requirements Using Spanner Wrench ...

Page 37: ...ar and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel Wheel Installation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on ...

Page 38: ...ce schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear Be sure to prop erly torque and install all wheel nuts Tire Pressure Inspection PSI Cold Front Rear 4 4 WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding a...

Page 39: ... 3 19 CYLINDER HEAD REMOVAL 3 19 CYLINDER HEAD INSPECTION 3 19 CYLINDER HEAD WARP INSPECTION 3 20 COMBUSTION CHAMBER INSPECTION 3 20 CYLINDER HEAD DISASSEMBLY 3 20 VALVE INSPECTION 3 21 VALVE SEAT RECONDITIONING 3 21 CYLINDER HEAD ASSEMBLY 3 24 VALVE SEALING TEST 3 24 ENGINE BOTTOM END DISASSEMBLY 3 25 CAM CHAIN GUIDE AND TESIONER BLADE 3 25 PISTON REMOVAL 3 25 CYLINDER INSPECTION 3 26 CYLINDER HO...

Page 40: ...ND PLAY ADJUST 3 36 CRANKCASE REASSEMBLY 3 37 CAM CHAIN OIL PUMP TENSIONER BLADE INSTALLATION 3 38 PISTON RING INSTALLATION 3 39 PISTON INSTALLATION 3 39 CYLINDER INSTALLATION 3 40 CYLINDER HEAD AND CAMSHAFT INSTALLATION 3 40 CAMSHAFT INSTALLATION TIMING 3 41 CAM CHAIN TENSIONER INSTALLATION 3 42 ROCKER ARM INSTALLATION 3 42 STARTER DRIVE ASSEMBLY 3 43 TROUBLESHOOTING 3 43 SPARK PLUG FOULING TROUB...

Page 41: ...ts 10mm Refer to Torque Procedure Cylinder Head 6mm Bolts 6mm 5 7 7 9 Nm Crankcase 6mm 6 5 8 0 9 11 Nm Crankshaft Sprocket Slotted Nut 25mm 34 46 Nm Flywheel Nut 16mm 66 81 90 110 Nm Oil Drain Bolt Crankcase 14mm 13 16 18 22 Nm Oil Filter Pipe Fitting Crankcase 20mm 9 5 12 13 16 Nm Oil Pressure Blind Plug 1 4 NPT 20 24 27 33 Nm Oil Pressure Relief Valve Plug 14 mm 15 17 20 23 Nm Recoil Housing 6mm...

Page 42: ...il to washer and threads of 10mm bolts 2 Tighten 10mm bolts in pattern below to 18 5 ft lbs 25 Nm 3 Loosen 180 degrees 4 Tighten to 11 ft lbs 15 Nm 5 Tighten 90 degrees 6 Tighten 60 degrees 7 Tighten 6mm head and base bolts to 8 ft lbs 11 Nm 2 4 5 6 1 6 mm Cylinder Head Cylinder Base 3 ...

Page 43: ...E EXPLODED VIEW Crankshaft Cylinder and Piston Cylinder Head Crankcase Valve Train 30 34 ft lbs 6 ft lbs 6 ft lbs 7 ft lbs 3 5 ft lbs 34 ft lbs 5 5 ft lbs 12 14 ft lbs 6 ft lbs SEE PROCEDURE 16 ft lbs 15 ft lbs 8 ft lbs 15 ft lbs 5 5 ft lbs ...

Page 44: ... Camshaft Chain Install new as a part of any crankshaft removal Cylinder Head Surface Warpage Limit 0020 05 mm Rocker Arm Shaft Rocker arm ID 8669 8677 22 02 22 04 mm Rocker shaft OD 8656 8661 21 987 22 00 mm Oil Clearance Limit 0039 10 mm Valve Clearance In Std 006 15 mm Ex Std 006 15 mm Valve Seat Angle Contacting Width In Std 039 1 0 mm Limit 055 1 4 mm Ex Std 059 1 5 mm Limit 070 1 8 mm Valve ...

Page 45: ...047 004 012 mm Degree of fit Push by hand fit 68o F 20o C Standard clearance 0 0005 0 012mm Piston Ring Piston Ring Installed Gap Top ring Std 008 0012 2 3 mm Limit 032 8 mm Second ring Std 018 019 35 50 mm Limit 039 1 0mm Oil ring Std 0079 0275 2 7 mm Limit 059 1 5 mm Piston Ring to Ring Groove Clearance Top ring Std 0006 0029 015 074 mm Limit 006 15 mm Second ring Std 0009 0025 025 065 mm Limit ...

Page 46: ...Std 0 006 012 15 30 mm Limit N A Counter Balancer Counter Balancer Shaft End Play Std 0 004 029 0 1 74 mm Limit N A Oil Pump Oil Pump Shaft End Play N A Oil Pump End Clearance Std 0 0027 0051 070 130 mm Limit N A Pump Rotor Tip Clearance Std 0 0047 12 mm Limit N A Pump Feed Rotor to Pump Body Clearance Std 0 006 008 15 21 mm Limit N A Oil Pressure Polaris 0W 50 Normal Operating Temperature Idle Sp...

Page 47: ...l Passage Stator Plate Counter Balance Gear Connecting Rod Big End Connecting Rod Small End Piston Skirt Rings Main Bearing Right Rear Cylinder Bolt Cylinder Head OIL FLOW DIAGRAM KEY Indirect Direct Rocker Arm Rocker Shaft Valve Springs Starting Clutch Crankcase Oil Passage RH Cam Journal Crankcase Oil Passage Accy Oil Cooler Fitting Location ES300PFE010 Main Bearing Starting Clutch One Way Clutc...

Page 48: ...The following components require engine removal for service Starting Clutch transmission removal required One Way Clutch engine braking Crankshaft Crankshaft Main Bearings Counter Balance Shaft or Bearings Crankcase Transmission NOTE Crankshaft components are not serviceable Replace crankshaft as an assembly ENGINE SERVICE ENGINE REMOVAL NOTE The engine removal procedure described below removes th...

Page 49: ...Disconnect gear indicator switch harness at transmission 11 Disconnect speed sensor from transmission left rear side 12 Rear fuel tank bracket 13 CVT air intake and exhaust ducts 14 Remove carburetor Insert a clean shop towel into the carburetor flange to prevent dirt from entering the intake port 15 Remove exhaust head pipe 16 Starter motor positive and negative cables at starter motor A B ...

Page 50: ...nnected Disregard the steps to remove recoil cover flywheel and stator from the engine 18 Front engine mount 19 Support lower sub frame with a stable platform jack 20 Rear lower engine mount 21 Sub frame bolts 2 each side 22 Rear wheel left side and brake caliper Re install rear wheel after caliper removal 23 Top rear shock bolts 24 Top bolts from sway bar bracket 25 Lower the jack and pull engine...

Page 51: ...ct inlet and outlet ducts for proper routing and sealing Inspect drive and driven clutch as described in chapter 8 Transmission Inspect transmission operation Exhaust Replace exhaust gaskets Seal connections if necessary with high temp sealant After running the engine verify all bolted exhaust connections are tight and in good condition Engine Mount Torque Inspect all engine mount fasteners and ve...

Page 52: ...ft and Right Side Covers Rear cab 6 Remove CVT cover and both clutches refer to CVT Chapter 8 7 Front prop shaft 4x4 models Drive pin out at front gearcase pull shaft back then forward Refer to Drive Chapter 8 Remove transmission linkage rod A and vent hose B 9 Disconnect gear indicator switch harness at transmission 10 Disconnect speed sensor at transmission left rear side 11 Rear fuel tank brack...

Page 53: ... pins in cover are release from engine case 27 Remove transmission out to the left side 28 Remove sway bar bracket from transmission 29 Refer to transmission disassembly in CVT Transmission Chapter 8 TRANSMISSION INSTALLATION NOTES 1 Install new gasket on engine 2 Install transmission to engine until alignment pins are engaged and screw in 4 bolts to hold in place but do not completely tighten at ...

Page 54: ...located behind the gas tank on the left side The breather provides ventilation for the valve cover and crankcase through the air box CAM CHAIN TENSIONER REMOVAL To position crankshaft at Top Dead Center TDC on compression stroke 4 Remove the valve cover 5 Rotate engine in normal direction and watch the intake valve open and begin to close 6 Continue to rotate engine slowly while watching camshaft ...

Page 55: ...SHAFT DISASSEMBLY AND INSPECTION NOTE Orientation of the components is important for reassembly Mark all components before disassembly 1 Remove the valve cover Be sure engine is positioned at TDC on the compression stroke there should be clearance on both rocker arm adjusters 2 Mark the rocker arms to keep them in order for assembly 3 Slide the rocker shaft out and be prepared to catch the wave wa...

Page 56: ...afts for out of round Inspect them for wear or damage Replace if excessive wear is evident NOTE Orientation of the rocker shafts is important for reassembly CAMSHAFT REMOVAL AND INSPECTION NOTE Cam chain tensioner must be removed before performing this procedure 1 Remove the camshaft end cover 2 Remove the sprocket bolt 3 Slip the chain over the sprocket and remove sprocket 4 If not removing the c...

Page 57: ...linder head and the two on the cylinder base 2 Loosen each of the four cylinder head bolts evenly 1 4 turn each time in a cross pattern until loose 3 Remove bolts A and tap the cam support tower with a plastic hammer until loose Remove 4 After removing the camshaft and securing the cam chain tap cylinder head lightly with a plastic hammer until loose CAUTION Tap only in reinforced areas or on thic...

Page 58: ...compress the valve spring more than necessary 2 Remove spring retainer and spring NOTE The valve springs should be positioned with the tightly wound coils A against the cylinder head 3 Push valve out keeping it in order for reassembly in the same guide 4 Measure free length of the inner and outer springs with a Vernier caliper Ill 1 Check spring for squareness as shown in Ill 2 Replace spring if m...

Page 59: ...easure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer Measure in two directions front to back and side to side 7 Subtract valve stem measurement to obtain stem to guide clearance NOTE Be sure to measure each guide and valve combination individually 8 Replace valve and or guide if clearance is excessive NOTE If valve guides are replaced ...

Page 60: ...utting oil to valve seat and cutter 3 Place 46o cutter on the pilot and make a light cut 4 Inspect the cut area of the seat If the contact area is less than 75 of the circumference of the seat rotate the pilot 180o and make another light cut If the cutter now contacts the uncut portion of the seat check the pilot Look for burrs nicks or runout If the pilot is bent it must be replaced If the contac...

Page 61: ...rrow and is a normal condition Look for an even and continuous contact point on the black marker all the way around the valve face 8 Clean all filings from the area with hot soapy water rinse and dry with compressed air 9 Lubricate the valve guides with clean engine oil and apply oil or water based lapping compound to the face of the valve Lapping is not required with an interference angle 10 Inse...

Page 62: ...r on springs and install valve spring compressor Compress spring only enough to allow split keeper installation and prevent loss of spring tension Install split keepers with the gap even on both sides 7 Repeat procedure for remaining valve 8 When all valves are installed tap lightly with soft faced hammer on the end of the valves to seat the Split keepers VALVE SEALING TEST 1 Clean and dry the com...

Page 63: ...ice procedures to access the bolt securing the tensioner blade to the crankcase PISTON REMOVAL 1 Remove one circlip Note valve pocket on intake side of piston for installation 2 Remove piston circlip and push piston pin out of piston If necessary heat the crown of the piston slightly with a propane torch CAUTION Do not apply heat to the piston rings The ring may lose radial tension 3 Remove the co...

Page 64: ... approximately 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered or cylinder centered on arbor and to bring the stones approximately 1 2 1 3 cm above and below the bore at the end of each stroke Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently deglazed and to ...

Page 65: ...o the direction of the piston pin 2 Subtract this measurement from the maximum cylinder measurement obtained earlier 3 Measure piston pin bore Replace piston if out of round 4 Measure piston pin O D Replace piston pin if out of round 5 Measure connecting rod small end ID Replace crankshaft if out of round Piston to Cylinder Clearance Std 0015 0032 0 038 0 082 mm Limit 0043 11 mm EXAMPLE OF CROSS H...

Page 66: ...boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with an oil rag immediately to remove residue and prevent rust FLYWHEEL REMOVAL INSPECTION 1 Remove the recoil housing recoil hub and flywheel nut 2 Install Flywheel Puller PN PA 47308 and remove flywheel CAUTION Do not hammer o...

Page 67: ...if out of round Replace worn bushings 5 Inspect gear teeth on starter drive Replace starter drive if gear teeth are cracked worn or broken CAM CHAIN DRIVE SPROCKET REMOVAL INSPECTION 1 Remove recoil housing flywheel flywheel key and stator 2 Using the Slotted Nut Socket remove the crankshaft slotted nut by turning it clockwise NOTE Slotted nut is left hand thread 3 Remove cam chain drive sprocket ...

Page 68: ...g clutch 1 Inspect the starting clutch drum bearing in the housing The shaft must turn smoothly by hand without binding in the clockwise direction and should not turn by hand in the counter clockwise direction Minimal movement in the shaft is NORMAL with engine removed due to the lack of clutch cover bearing support on the free end of the shaft approximately 0 060 0 1 5mm Press the shaft out of th...

Page 69: ...ure the thickness of the friction material on the shoes as shown from the bottom of the friction material to the top at the thinnest point STARTING CLUTCH ASSEMBLY 1 Clean the mating surfaces of the crankcase and clutch starting clutch housing to remove all gasket material 2 Install the starting clutch on the shaft 3 Start a NEW stake nut on the shaft 4 Install the starting clutch holder on the cl...

Page 70: ... disassemble and inspect the one way clutch and hub CRANKCASE DISASSEMBLY NOTE Engine must be removed from the frame to perform any crankcase or crankshaft removal NOTE The starter starter drive flywheel stator oil pump and transmission can be serviced with the engine in the frame CRANKCASE SEPARATION NOTE Stator housing flywheel and gears have are previously removed for this procedure Use care du...

Page 71: ...p and down movement The MAG end bearing usually stays in the case Check the inner race of the MAG bearing in the same manner 2 Replace the main bearings if the components fail visual inspection 3 The connecting rod utilizes a roller bearing Clearance can be measured with a dial indicator to check radial clearance Visually inspect the connecting rod crank pin and thrust washers for scoring damage e...

Page 72: ...urn smoothly and quietly The outer race should fit tightly in the crankcase The inner race should be firm with minimal side to side movement and no detectable up and down movement 2 To remove balance shaft bearings use a blind hole bearing puller NOTE Bearings are stressed during the removal procedure and should not be re used CRANKCASE OIL PICKUP STRAINER INSPECTION 1 Pull the strainer screen A f...

Page 73: ...dure is the same but the photo examples will differ 1 Make sure all bearings are firmly seated in the crankcase 2 Lay a straightedge on the left PTO crankcase and measure the distance from the straightedge to the bottom of the main bearing bore if bearing is still on the crankshaft or to the bearing race if the bearing is installed in the case using a dial caliper 3 Subtract the thickness of the s...

Page 74: ...is that measurements are taken to the balance shaft bearings in the case rather than the crankshaft main bearings and the width of the balance shaft is measured not the crankshaft 1 Make sure the counterbalance shaft bearings are firmly seated in each crankcase 2 Measure the distance from the Mag crankcase mating surface to the balance shaft bearing using a dial caliper and a straight edge Subtrac...

Page 75: ...ase 1 Place the required shims on the crankshaft and balance shaft 2 Support the PTO side crankcase on blocks Install the crankshaft and balance shaft in the case aligning the balance dots on the gears 3 Be sure balance dots on gear teeth are aligned 4 Apply a thin coat of crankcase sealant to the outer mating surface of the left crankcase Sealant is not required on the inner mating surfaces A 5 I...

Page 76: ...tor plate seal and bushing with engine oil and install the stator plate 6 IMPORTANT Be sure the sealed screw is placed in the hole that aligns with the cam chain cavity or an oil leak may result If you are installing the old screw seal it with Loctite 242 blue before installation 7 Torque the screws to specification 8 Install the flywheel key and flywheel Tensioner Blade Mounting Bolt Torque 5 6 5...

Page 77: ...rings by checking to be sure the top and second rings rotate freely in the groove when compressed by hand PISTON INSTALLATION 1 Install a new circlip on one side of the piston with the end gap facing up or down 2 Apply clean engine oil to the piston rings ring lands piston pin bore piston pin and piston skirt Lubricate the connecting rod both ends and crankshaft main bearing area 3 IMPORTANT Insta...

Page 78: ...ge to the chain drive sprocket teeth or tensioner blade 5 Loop the cam chain through the cylinder chain room and secure with mechanic s wire 6 Install cylinder carefully with a front to back rocking motion until rings are fully captive in the sleeve then remove the compressor and support block 7 Seat the cylinder firmly onto the base gasket 8 Install the cam chain guide and dowel pins into the cyl...

Page 79: ...e timing inspection hole 1 Rotate the crankshaft until the T Top Dead Center timing mark on the flywheel is aligned with the mark in the timing inspection window of the recoil housing Be sure to use the correct mark when installing the cam Do not use any advance timing marks 2 Apply engine oil or starter drive grease molybdenum disulfide paste to the camshaft main journals and cam lobes Lubricate ...

Page 80: ...en and push the plunger B in to the fully retracted position 2 With the plunger retracted install the tensioner assembly with a new gasket and tighten the bolts to specification 3 Install the pin spring and tensioner cap with a new sealing washer Torque cap to specification 4 Slowly rotate engine two to three revolutions in the direction of rotation and re check cam timing ROCKER ARM INSTALLATION ...

Page 81: ... drive bushings in the cases and all moving surfaces of the starter drive gears and install 3 Install recoil housing and torque bolts to specification TROUBLESHOOTING SPARK PLUG FOULING TROUBLESHOOTING Restricted air filter main or pre cleaner or air inlet ducts Choke cable adjustment or plunger cable sticking Foreign material on choke plunger seat or plunger Incorrect spark plug heat range or gap...

Page 82: ... Carburetor misadjusted Choke not adjusted properly or sticking plunger Low compression Crankcase breather restricted Air filter restriction Engine Idles But Will Not Rev Up Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect or restricted carburetor jetting ETC switch limiting speed Reverse speed limiter limiting s...

Page 83: ...arbon accumulated on valve area Rocker arm sticking Backfiring ETC or speed limiter system malfunction Fouled spark plug or incorrect plug or plug gap Carburetion faulty lean condition Intake Exhaust system air leaks Ignition system faulty Spark plug cap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key Poor connections in ign...

Page 84: ...NOTES ENGINE 3 46 ...

Page 85: ...ARTER SYSTEM CHOKE OR ENRICHMENT 4 8 PILOT IDLE AND SLOW SYSTEM 4 8 MAIN SYSTEM 4 9 FLOAT SYSTEM 4 9 PILOT SCREW 4 10 AIR FUEL MIXTURE RATIO 4 10 JET NEEDLE 4 11 NEEDLE JET 4 11 THROTTLE OPENING VS FUEL FLOW 4 11 CARBURETOR DISASSEMBLY MIKUNI CV 4 12 CARBURETOR CLEANING 4 13 CARBURETOR INSPECTION 4 13 CARBURETOR ASSEMBLY 4 14 FLOAT HEIGHT ADJUSTMENT 4 14 NEEDLE AND SEAT LEAKAGE TEST 4 15 FUEL LEVE...

Page 86: ...nd refuel outdoors or in a well ventilated area Do not overfill the tank The tank is at full ca pacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an en closed area Gasoline powered engine ex haust fumes are poisonous and can cause loss of consciousness and death in a short time Never drain the float bowl when the eng...

Page 87: ...mponents Reference Description Reference Description A Jet Needle J Throttle Control Cover Plate B Diaphragm Assembly K Carburetor Body C Needle Jet L Enrichment Plunger D Jet Block Assembly M Enrichment Spring E Washer N Cable guide F Main jet P Pilot Air Jet G Cover H Spring A B C D E F G H J K L M N P ...

Page 88: ...ence Description A Throttle Plate Shaft Retaining Components J Float Bowl O Ring B Pilot Jet K Float Bowl C Needle Valve Assembly L Float Bowl Drain Screw D Throttle Plate M Throttle Shaft E Idle RPM Speed Adjustment Screw N Throttle Shaft Return Spring F Spring G Needle Valve Retaining Plate H Floats A B C D E F G H J K L M N ...

Page 89: ...4 5 FUEL SYSTEM CARBURETION Carburetor Venting System Table 4 3 Carburetor Venting System Reference Description A Check Valve B Hose Float Bowl Drain C Hose Vents D Tee Fitting E Filter A B C D E ...

Page 90: ...us engine damage Select the correct main jet carefully for elevation and temperature according to the charts in the Specifications section or in the Owner s Safety and Maintenance Manual for each particular model Carburetor Component Function System Main Components Main Function Main Affect Float System Level Control Inlet Pipe Needle and Seat Float Float Pin Maintains specified fuel level in floa...

Page 91: ...er below the diaphragm is vented to atmospheric pressure by a passage on the air box side of the carburetor A spring installed in the center of the vacuum slide dampens the slide movement and assists the return of the slide When the throttle plate is opened and engine speed begins to increase the pressure in the venturi and therefore in the chamber above the diaphragm becomes significantly lower t...

Page 92: ...a passage 8 extending from underneath the diaphragm The rich fuel air mixture for starting is discharged through starter outlet 6 in the main bore 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 3 where it mixes with air coming in through pilot air jet 4 The mixture th...

Page 93: ... is determined ultimately by throttle position and vacuum slide height FLOAT SYSTEM Fuel enters the float chamber 3 by means of the inlet pipe and passage through a screen on the back of the inlet needle seat 4 and around the inlet needle 2 As the fuel fills the float chamber the float 1 rises and forces the inlet needle against the seat shutting off the orifice in the seat When fuel level is up i...

Page 94: ...tapers off at one end and the clearance between the jet needle and the needle jet increases as the throttle valve opening gets wider The air fuel mixture ratio is controlled by the height of the E clip inserted into one of the five slots provided in the head of the jet needle The previous chart shows the variation of fuel flow based on the height of the E clip CAUTION The pilot screw is calibrated...

Page 95: ...le taper starts coming out of the jet sooner resulting in a richer mixture Moving the clip higher produces a leaner mixture If the taper is worn due to vibration fuel flow may be significantly affected NEEDLE JET The needle jet works in conjunction with the jet needle to regulate fuel flow rate An air bleed opening in the side of the needle jet brings in air measured by the air jet This air initia...

Page 96: ...owl Remove the float pin screw The float and float pin can be removed 3 Remove inlet needle seat retaining screw along with plate and carefully remove needle seat NOTE Do not use a pliers to remove the seat or permanent damage may occur 4 Remove the pilot mixture screw spring flat washer and O Ring If an anti tamper plug is installed over the pilot screw cavity it must be removed for access NOTE T...

Page 97: ...both the needle and needle jet to prevent a rich condition TIP A worn needle jet is difficult to spot To check slide a slightly larger new jet needle into the needle jet and hold it to a light source Light will be visible between the needle and needle jet if it is worn 2 Inspect the inlet needle tapered surface for any sign of wear or damage Be sure the spring loaded pin is free moving and returns...

Page 98: ...k out the specified number of turns NOTE The final pilot idle mixture must be adjusted with the engine running Refer to Page 2 10 FLOAT HEIGHT ADJUSTMENT 1 Illustration 1 Place the throttle side of the carburetor on a level surface to remove weight from float arm In this position the float tongue will rest slightly outward 2 Illustration 2 With the carburetor still resting on the level surface use...

Page 99: ...t O ring FUEL LEVEL TEST A fuel level test can be performed on some models if the drain hose fitting is accessible Be sure to re attach the bowl drain hose after performing the test A fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetor The fuel level can be observed with the engine either running or shut off however engine must run briefly...

Page 100: ...tric choke inoperative Incorrect pilot air fuel screw adjustment Faulty inlet needle and seat Faulty inlet needle seat O Ring Float level too high Poor fuel quality old fuel Loose jets Worn jet needle needle jet or other carburetor parts Dirty carburetor air bleed passages or jets POOR IDLE Idle Too High Idle adjusted improperly idle mixture screw damaged Sticky vacuum slide Throttle cable stickin...

Page 101: ...em Table 4 4 Air Intake System Reference Description Reference Description A Pre Filter J Crankcase Breather Hose B Air Filter C Intake Box Snorkel D Intake Box Cover E Cover Seal F Crankcase Breather Foam G Intake Box Drains H Carburetor Snorkel A B C D E F G H J ...

Page 102: ...uel Cap J Hose Fuel Tank To Supply petcock B Fuel Cap O Ring K Fuel Pump C Fuel Level Gauge L Hose Fuel Pump To Carburetor D Fuel Tank Vent M Hose Fuel Pump To Carburetor Vacuum Impulse E Fuel Tank Hold Down Bracket Pad N Fuel Filter Arrow points in direction of fuel flow to carburetor F Fuel Tank G Fuel Supply Petcock H Hose Supply Petcock To Fuel Pump A B C D E F G H J K L M N ...

Page 103: ...4 19 FUEL SYSTEM CARBURETION EXHAUST SYSTEM Exhaust System Table 4 6 Exhaust System Reference Description A Tip Spark Arrestor B Muffler C Pipe Clamp D Gasket E Head Pipe F Flange Gasket A B C D E F ...

Page 104: ...NOTES FUEL SYSTEM CARBURETION 4 20 ...

Page 105: ...ION 5 8 POD EXPLODED VIEW 5 9 POD KEY SWITCH CHOKE SPEEDO CONNECTION REMOVAL INSTALLATION 5 10 STEERING 5 10 HANDLEBAR REMOVAL 5 10 HANDLEBAR INSTALLATION 5 10 STEERING POST REMOVAL 5 11 STEERING POST BEARING REPLACEMENT 5 12 STEERING POST INSTALLATION 5 12 STEERING A ARM 5 14 EXPLODED VIEW 5 14 A ARM 5 15 A ARM REMOVAL 5 15 A ARM ASSEMBLY 5 15 FRONT STRUT CARTRIDGE REPLACEMENT 5 16 FRONT STRUT RE...

Page 106: ...ccur 2 Next use the diagonal side cutters under outside insert B to completely remove the assembly NOTE The inside insert A will still be installed in the outside insert B NOTE The inside insert A will still be installed in the outside insert B 3 To install the inserts press outside insert B into the hole Press inside insert A until it snaps into place NOTE The outside insert B should be flush sur...

Page 107: ...f the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel Pull the panel downward and rearward to remove it from the ATV 3 Reinstall the side panel by reversing the removal procedure FRONT CAB FENDER ...

Page 108: ...artment 7 Route the battery cables through the front compartment 8 Remove the front cab fasteners 8 9 Remove the plastic rivets from the footwells 10 Carefully lift off the front cab FRONT CAB FENDER INSTALATION For this procedure please refer to the diagram on page 5 3 1 Carefully place front of the cab onto the frame 2 Route the battery connections through the cab and into the battery box 3 Inse...

Page 109: ...the frame footwells 11 14 4 Disconnect the rear lights 5 Lift the rear cab 4 from the frame 6 Reverse the removal steps for installation FOOTWELL REMOVAL INSTALLATION 1 Remove the plastic inserts A that secure the wheel well to the front and rear cabs See PLASTIC INSERT on page 5 2 2 Remove the screws B from the bottom of the foot well Remove the footwell 3 Reverse the removal procedures to instal...

Page 110: ...5 6 BODY AND STEERING BODY RACK EXPLODED VIEW REAR RACK REMOVAL INSTALLATION 1 Remove the fasteners 2 3 7 9 10 and 11 2 Remove the rear rack 3 Replace in reverse order ...

Page 111: ...5 7 BODY AND STEERING POD EXPLODED VIEW ...

Page 112: ...g the ignition nut 9 counter clock wise 4 Remove the choke connection by turing the choke nut 14 counterclockwise 5 Remove the choke cable 13 from the pod 6 Replace in reverse order of removal STEERING HANDLEBAR REMOVAL 1 Remove the handlebar pod See POD KEY SWITCH CHOKE SPEEDO CONNECTION REMOVAL INSTALLATION on page 5 8 2 Remove the handlebar block fasteners and A the mounting bracket B 3 Remove ...

Page 113: ... the steering post dimple D 3 Insert the bolts through the top of the handlebar block 4 Place the mounting bracket B onto the bottom of the steering post and install the nuts on the bolts 5 Evenly torque the two front nuts to 12 ft lb 16Nm 6 Torque the rear nuts evenly to 12 ft lb 16Nm NOTE There will be a slight gap on the backside of the blocks after the procedure is performed 7 Replace the hand...

Page 114: ...valve to the OFF position 6 Remove the fuel line B from the fuel pump C 7 Remove the vent line from the frame that comes from the top of the fuel tank Note the vent line routing 8 Remove the fuel tank from the frame 9 Remove the steering tie rod ends D from the steering bracket E Note the orentation of the fasteners and bracket on the steering assembly 10 Remove the steering post bracket F at the ...

Page 115: ...TALLATION 1 Insert the steering post assembly into the chassis 2 Place the lower bracket F into the front gear case on the 4x4 units and into the bracket on the 2x4 units 3 Apply blue Loctite to the threads of the bracket bolts 4 Torque the bolts to 19 22 ft lb 26 30Nm 5 Place the steering post upper bracket to the frame torque the upper nuts to 22 ft lb 30Nm 6 Place the tie rod retainer H on to a...

Page 116: ...t 12 Tighten the fuel tank bracket fasteners 13 Hook up the fuel line to the fuel pump and move the clamp to the correct area STEERING A ARM Exploded View NOTE To avoid damage to tie rods and other steering components be sure to install tie rod end bolts in the proper direction The steering post arm bolt B points up the rod end bolts A point down Be sure inner rod ends are placed between the A B ...

Page 117: ...ush guard 15 if applicable 2 Place the A Arm to the frame and insert the flange bolt 19 with the head toward the front of the machine and the flange nut 3 toward the rear 3 Torque the flange bolt 19 to 40 ft lbs 54Nm 4 Insert the ball joint 13 far enough into the carrier bearing assembly so that the pinch bolt 10 can be inserted 5 Insert the pinch bolt 10 so that the flange head is at the front of...

Page 118: ...3 1 Place strut assembly into the frame and insert the strut flange nut 16 2 Insert the strut into the carrier bearing assembly and insert the fasteners 4 7 3 Torque the top strut flange nut 16 to 40 ft lb 54 Nm 4 Torque the carrier bearing fasteners 7 to 37 ft lb 50Nm 5 Replace the torx fastener that holds the brake line in place 6 Replace front cab BEARING REPLACEMENT Refer to drawing on page pa...

Page 119: ...ee A ARM REMOVAL on page 5 13 2 Remove the snap ring 1 from the ball joint 3 Press out the old ball joint 2 4 Press in new ball joint into A Arm 5 Replace the snap ring 1 onto the new ball joint 6 Assemble the A Arm See A ARM ASSEMBLY on page 5 13 REAR SUSPENSION 1 2 ...

Page 120: ...x short grey bushings 2 and pivot shafts 3 14 6 Remove the Lower Control Arm LCA 11 fasteners 4 5 12 from the frame and bearing carrier Note the long 5 8 and short 12 14 fasteners and pivot shaft locations 7 Remove the long grey bushings 9 and pivot shaft 8 from the frame 8 Remove the short bushings 13 and pivot shaft 14 from the bearing carrier 9 Remove the LCA 11 from the unit 10 Replace in reve...

Page 121: ...5 17 BODY AND STEERING ...

Page 122: ...5 18 BODY AND STEERING ...

Page 123: ...5 19 BODY AND STEERING ...

Page 124: ...NOTES BODY AND STEERING 5 20 ...

Page 125: ... FLUID CHANGE 6 7 BRAKE BLEEDING 6 8 HAND BRAKE MASTER CYLINDER 6 9 REMOVAL 6 9 INSTALLATION 6 10 BRAKE PADS 6 11 REMOVAL 6 11 INSTALLATION 6 12 FRONT CALIPER 6 12 REMOVAL 6 12 INSPECTION 6 14 REASSEMBLY 6 15 INSTALLATION 6 15 BRAKE BURNISHING PROCEDURE 6 16 OVERVIEW 6 16 BRAKE DISC 6 16 THICKNESS RUNOUT INSPECTION 6 16 WEAR INSPECTION 6 16 REMOVAL REPLACEMENT 6 17 FOOT BRAKE 6 17 FOOT PEDAL REMOV...

Page 126: ...c Runout 010 254 mm Caliper Piston Diameter Front 1 250 31 75 mm Table 6 2 REAR BRAKE Item Standard Service Limit Brake Pad Thickness 275 7 mm 155 3 9 mm Brake Disc Thickness 157 4 0 2 mm 140 3 55 mm Brake Disc Thickness Variance Between Measurements 002 051 mm Brake Disc Runout 010 254 mm Caliper Piston Diameter Rear 1 250 31 75 mm Table 6 3 TORQUE SPECIFICATIONS Item Torque ft lbs in lbs Torque ...

Page 127: ... disc noise or premature pad wear Adjust pad stop front calipers Insufficient lever or pedal clearance Set to proper level Master cylinder reservoir overfilled Check brake fluid level adjust as needed O rings worn Rebuild Caliper Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Clean piston s seal Operator error riding the ...

Page 128: ...N COMPONENTS System Exploded View All Banjo Style Fittings 15 ft lbs 20 Nm All Flare Style Fittings 12 15 ft lbs 16 21 Nm All Bleed Screws 36 46 in lbs 4 5 Nm Apply a Light Amount of Pipe Sealant to Threads 2 screws 7 in lbs 79Nm ...

Page 129: ...iew HYDRAULIC BRAKE SYSTEM A B D E F G H C A Bleeder Screw B Caliper Body C Internal Caliper Slide Pin O rings small D Square Seals E Piston F Caliper Mount G Brake Pads H Internal Caliper Slide Pin O rings large I Caliper mount O ring I ...

Page 130: ...is the compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the lever is released and the master cylinder piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion heated fluid or contraction cooled fluid During system service be sure this port is open Due to the high temperatures create...

Page 131: ...moves freely on guide pins where applicable Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely BRAKE BLEEDING Fluid Change NOTE When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder NOTE Do not move brake lever when reservoir fluid level is low This procedure should be used to change f...

Page 132: ...er D until pressure builds and holds 3 While maintaining lever pressure open bleeder screw Allow lever to relax slowly toward the hand grip while tightening the bleeder screw Watch for signs of air bubbles in the fluid as the screw is tightened When no air is present the bleeding procedure should be complete 4 Allow lever to return back to it s normal position once the brake bleeder is securely ti...

Page 133: ...nspect all hoses and lines for wear or abrasion Replace hose if wear or abrasion is found HAND BRAKE MASTER CYLINDER Removal 1 Clean master cylinder and reservoir assembly Make sure you have a clean work area to disassemble brake components 2 Remove the banjo bolt that connects the brake line to the master cylinder Discard the copper washers 3 Remove master cylinder clamps from handlebars 4 Hold b...

Page 134: ...irst as indicated in the illustration to the right NOTE To speed up the brake bleeding procedure the master cylinder can be purged of air before brake line is attached Fill with DOT 3 or DOT 4 Brake Fluid and pump lever slowly two to three times with finger over the outlet end to purge master cylinder of air 2 Place NEW sealing washers on each side of banjo line and torque banjo bolt to specificat...

Page 135: ...ting port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 4 Push mounting bracket inward and slip outer brake pad past edge Remove inner pad 5 Measure the thickness of the pad material Replace pads if worn beyond the service limit CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may oc...

Page 136: ... from entering the brake system 5 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 6 Install wheels and torque wheel nuts to specification NOTE Front Wheel Nut Torque Refer to Torque Table at beginning of chapter FRONT CALIPER Removal 1 Using a line wrench loosen and remove brake line to caliper Place a container under caliper to catch fluid WARNING If t...

Page 137: ...ainer or the brake pad ears 3 Remove mounting bracket pin assembly 4 Remove piston using a twisting pulling motion Remove the piston square seals using a wooden or plastic pick Use caution not to scratch or damage the piston or the bore of the caliper NOTE Do not use a metal pick or awl to remove the square seals The use of compressed air may be required to remove the piston CAUTION Always wear ey...

Page 138: ...sed spray to clean the caliper Inspection 1 Inspect caliper body for nicks scratches or wear Measure bore size and check for out of round Replace if damage is evident or if worn 2 Inspect piston for nicks scratches 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 BRAKE PAD IN...

Page 139: ... Season Grease PN 2871423 on the square seals The petroleum based lubricant will cause the square seals to swell up 4 Compress the mounting bracket into the caliper and make sure the O rings are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease Installation 1 Install caliper on hub strut and torque mounting bo...

Page 140: ... scratches or damage 2 Measure the disc thickness at eight different points around the pad contact surface using a 0 1 micrometer Replace disc if worn beyond service limit 3 Mount dial indicator as shown to measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Wear Inspection 1 visually inspect disc for scoring scra...

Page 141: ...t lbs 24 Nm FOOT BRAKE Foot Pedal Removal Install 1 Remove the cotter key A 2 Remove the washers bushings and tension spring and remove the brake lever F 3 Reverse the steps for installation using a new cotter key during installation Brake Disc Thickness New 157 4 0 2mm ServiceLimit 140 3 556 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements Brake Disc Runou...

Page 142: ...leeding section of this manual TROUBLESHOOTING BRAKE SQUEAL Dirty contaminated friction pads Improper alignment Worn disc Worn caliper POOR BRAKE PERFORMANCE Air in system Water in system brake fluid contaminated Caliper disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incorrectly adjusted lever Incorrectly adjusted stationary pad Worn o...

Page 143: ...W 7 8 FRONT DRIVE SHAFTS AND PROPSHAFTS 7 8 FRONT GEARCASE CENTRALIZED HILLIARD 7 9 OPERATION OVERVIEW 7 9 FRONT GEARCASE 7 10 CENTRALIZED HILLIARD EXPLODED VIEW 7 10 ALL WHEEL DRIVE GEARCASE 7 11 REMOVAL 7 11 DISASSEMBLY 7 12 REASSEMBLY 7 15 AWD DIAGNOSTICS AWD WILL NOT ENGAGE 7 17 INSTALLATION 7 18 REAR HUB 7 19 REMOVAL 7 19 DISASSEMBLY 7 20 REAR HUB ASSEMBLY 7 21 INSTALLATION 7 21 REAR CV SHAFT...

Page 144: ...8 Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly Hub removed for clarity removal optional Table 7 1 Torque Table Component ft lbs in lbs Nm F R Steel Wheel Nuts 27 41 F R Aluminum Wheel Nuts 90 122 Front Hub Nut 80 109 Rear Hub Nut 80 109 Lower Front A arm 38 51 CAUTION Locking nuts and bolts with pre applied locking agent should be replaced if rem...

Page 145: ...Inspection Check the front and rear driveshaft CV boots for signs of cracking tearing punctures or leaking grease If the driveshaft boot loses all of the grease CV joint failure will occur Disassembly 1 Refer to the CV SHAFT REMOVAL section in this chapter for procedures 2 Remove clamps from rubber boot using the proper boot clamp pliers 3 Remove the large end of the boot from the CV joint slide t...

Page 146: ... axle 6 Add grease through large end of boot 7 Install a new boot onto the axle shaft and fill the CV joint and boot with the correct type and amount of grease 8 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in th...

Page 147: ...outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged Installation 1 Support bottom of hubstrut housing in a press or suitable device 2 Start bearing in housing 3 Press bearing into place until outer race bottoms on housing 4 Install snap ring into groove FRONT PROP SHAFT Removal 1 Using Roll Pin Removal Tool PN 2872608 remove the roll pin from prop shaft at ...

Page 148: ...ation of grease fitting and mark inner and outer yoke for correct re positioning during installation 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing ca 4 Force U joint cross to one side and lift out of inner yoke CAUTION Always wear eye protection ...

Page 149: ...ntinually check for free movement of bearing cross as bearing caps are assembled are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure for other side 4 Install snap ring to contain bearing cap just installed Repeat procedure for other side 5 Install snap ring to contain bearing cap just installed Repeat procedure for other side 6 Seat all bearing caps against sna...

Page 150: ...manual for the proper replacement parts Drive Axle Components Drive Boot Replacement Kits Front Prop Shaft Components Outer Clamp Boot Clamp 4 oz grease Propshaft Assy Cross Bearing Kit Prop Shaft Yoke Prop to Transmission Yoke Front Gearcase 4 oz Clamps Outer CV Joint Inner Boot Inner CV Joint Outer Boot Shaft ...

Page 151: ...agnetic field This magnetic field attracts an armature plate keyed to a roller cage that contains rollers and roller cam The difference in rotational rpm between the input shaft and front axles forces the rollers up the external cam The rollers engage themselves to the output hubs that link both front axles resulting in True All Wheel Drive Disengagement As the front and rear wheels gain traction ...

Page 152: ...7 10 FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD EXPLODED VIEW ...

Page 153: ...ent line 6 Remove the front bumper 4 Bolts 7 Remove the front splash guards two screws and six slips per side 8 Remove the center tank cover replace gas cap to avoid spills 9 Remove the front cab by loosening the 4 screws that attach the cab to the frame Turn the handlebars full left Rotate and lift the front cab around the steering components 10 Remove the fuel tank Chapter 4 11 Remove the steeri...

Page 154: ...rcase 15 Remove the roller pin from the front prop shaft Use the Roller Pin Removal Tool PN 2872608 16 Remove bolts securing bottom of housing to frame Bolts are accessible through the skid plate Remove vent line Remove the front gearcase from either side of frame DISASSEMBLY 1 Drain and properly dispose of used oil Remove any metal particles from the drain plug magnet 2 Remove bolts and output sh...

Page 155: ...y from the left hand gearcase half Inspect surfaces for wear or signs of damage Replace component if found to worn or damaged 6 Remove the ring gear roll cage assembly rollers and H springs from the gearcase 7 Thoroughly clean all parts Inspect the rollers A for nicks and scratches The rollers must slide up and down freely within the roller cage surfaces B 8 Inspect the ring gear C for consistent ...

Page 156: ...ing Replace if wear or damage is found 12 Inspect the output hub bearings arrows Replace bearings if wear or damage is found NOTE Due to extremely 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 smoothly and quietly with no detectable up and down movemen...

Page 157: ...e pinion gear O for chipped broken or missing teeth Replace the input cover O ring and seal 16 Inspect the output shaft bushing arrow Replace as needed Clean the inside surfaces of both gearcase halves 17 Remove and replace the O rings and seals arrows from the gearcase halve assemblies REASSEMBLY 1 Replace all O rings seals and worn components 2 Press the pinion shaft seal into the pinion cover u...

Page 158: ...he rollers and roll cage into the ring gear Insert the rollers as the roll cage is installed installing the lower row first and then the upper row 6 Install the ring gear over the output hub and into the output cover Insert the backlash pad G and set assembly upright 7 Install the armature plate D onto the ring gear Verify the plate tabs are places into the slots on the roller cage NOTE Verify bac...

Page 159: ...arness The gearcase coil should measure between 21 6 ohms and 23 9 ohms 68 F 20 C 2 Check the minimum battery voltage at the wire that feeds the hub coil wire There should be a minimum of 11 80 12 0 Volts present for proper operation 3 Inspect the armature plate for a consistent wear pattern There should one or two distinct wear bands one band inside the other If only one band of wear is present o...

Page 160: ... gap If the pole gap increases the coil will not be strong enough to engage the AWD system 5 Inspect the rollers for nicks and scratches The rollers must slide up and down and in and out freely within the roll cage sliding surfaces INSTALLATION 1 Install gearcase into the frame Torque mounting bolts to 30 ft lbs 41 Nm 2 Coat splines with anti seize compound Install CV shaft into the gearcase Light...

Page 161: ...wer the front of the ATV 9 Torque the wheel nuts to specification 10 Add the proper lubricant to the front gearcase Check drain plug for proper torque Refer to Chapter 2 for fluid fill and change information REAR HUB Removal 1 Place the ATV in Park and lock the parking brake Remove rear hub cap and loosen wheel nuts 2 Remove cotter pin A 3 Loosen the hub retaining nut B 4 Loosen the wheel nuts C 5...

Page 162: ...L DRIVE 8 Remove hub nut domed washer and flat washer 9 Remove hub 10 Remove upper control arm bolt as shown 11 Remove both lower control arm bolts 12 Remove bearing carrier Disassembly 1 Remove outer snap ring ...

Page 163: ...he bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged Rear Hub Assembly 1 Support bottom of bearing carrier housing 2 Start bearing in housing 3 Press bearing into place until outer race bottoms on housing 4 Install snap ring in...

Page 164: ...gn holes if required 10 Install hub cap REAR CV SHAFT Removal 1 Remove rear hub see REAR HUB REMOVAL 2 Tip hub outward and remove shaft from hub 3 Pry and pull sharply outward to remove shaft from transmission Install a new lock ring upon assembly DRIVE SHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints Driveshaft components are precisio...

Page 165: ... clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV joints and CV joint boots REAR CV SHAFT INSTALLATION 1 Slide shaft assembly into bearing carrier hub 2 Apply anti seize compound to splines of shaft 3 Install a new lock ring and install the shaft 4 Lift bearing carrier into place ...

Page 166: ...joint inner hub to locate snap ring 2 Open the snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft with a soft faced hammer while holding snap ring open 3 Place a new snap ring in the groove of the CV joint inner hub with tabs facing the shaft as shown A Snap Ring Snap Ring Located in recessed area Tap CV housing off shaft Spread ends of snap ring to remove join...

Page 167: ...placed without cleaning the CV joint Use the recommended amount of grease for boot replacement only see below Proceed to Boot Installation 3 Thoroughly clean and dry the CV joint and inspect ball tracks and cages for wear cracks or other damage NOTE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if c...

Page 168: ...all end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot 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 ...

Page 169: ...PECIAL TOOLS 8 3 CVT OPERATION 8 4 CVT OPERATION OVERVIEW 8 4 STARTING CLUTCH OPERATION 8 4 DRIVE CLUTCH OPERATION 8 4 DRIVEN CLUTCH OPERATION 8 4 ENGINE BRAKING CLUTCH 8 5 CVT MAINTENANCE INSPECTION 8 5 CVT DRYING 8 5 CVT OVERHEATING DIAGNOSIS 8 6 CVT SYSTEM DISASSEMBLY DRIVE CLUTCH 8 8 CVT SYSTEM DRIVEN CLUTCH SERVICE 8 10 TRANSMISSION 8 13 TRANSMISSION SERVICE 8 14 TRANSMISSION DISASSEMBLY 8 14...

Page 170: ...8 2 CVT TRANSMISSION TORQUE SPECIFICATIONS CVT TORQUE SPECIFICATIONS 96 in lbs 10 8 Nm 185 ft lbs 250 Nm 14 ft lbs 19 Nm Clamps 25 in lbs Use Clutch Holder PA 47478 ...

Page 171: ...inkage rod out of bushing clip to remove 2 Remove bolts attaching gear selector mount to frame 3 To remove gear selector handle pry cap off and remove screw SPECIAL TOOLS SPECIAL TOOLS Order tools from SPX Corp 1 800 328 6657 Clutch Compression Tool 8700220 Arm Clutch Spring Compressor Use with 8700220 PA 47457 1 Clutch Adaptor PA 47457 2 Spring Retainer Alignment Tool PA 47457 3 Retainer Nut Sock...

Page 172: ...hen engine RPM reaches engagement speed and the starter clutch engages At low RPM the drive belt is located at the bottom smallest diameter of the drive clutch sheaves resulting in a low gear ratio As engine RPM increases centrifugal force moves the drive clutch shift rollers outward in their respective tracks toward the outside of the drive clutch This forces the moveable sheave farther inward to...

Page 173: ...components Refer to the troubleshooting checklist for more information 1 Drive and Driven Clutch Rollers Weights Buttons and Bushings and Driven Clutch Spring Inspect for wear 2 Drive Belt Inspect condition and width of belt 3 Sheave Faces Clean and inspect for wear 4 CVT System Sealing The CVT system is air cooled by fins on the drive clutch stationary sheave The fins create a low pressure area i...

Page 174: ...perated in LOW RANGE if equipped when pulling or plowing heavy loads or if extended low speed operation is anticipated GENERAL RANGE OPERATION GUIDELINES Low Range if equipped Heavy pulling basic operational speeds less than 7 MPH riding through rough terrain swamps mountains etc low ground speeds High Range High ground speeds speeds above 7 MPH Diagnosis of Clutch Drive Belt Cover Related Issues ...

Page 175: ...nitial vehicle movement increases CVT temperatures and component wear Towing Pushing at low RPM low ground speed Use Low Range only if equipped Plowing snow dirt etc utility use Use Low Range only if equipped Stuck in mud or snow Shift the transmission to Low Range if equipped carefully use fast aggressive throttle application to engage clutch Warning Excessive throttle may cause loss of control a...

Page 176: ...Fit should be snug with no tightness or sticking Rotate the inner race to be sure it rotates freely without binding after installation 5 Install the snap ring Be sure it is fully seated in the groove 6 Inspect the CVT cover gasket and replace if damaged 7 Before removing drive belt install the tool as shown to prevent drive clutch moveable sheave from moving inward NOTE If tool is not available us...

Page 177: ...ns for damage the sleeve for wear or rough spots and the face of the fixed sheave for wear grooving or rough surface 12 Remove the rollers from the primary sliding sheave Check the rollers for wear deep scoring or flat spots Remove and inspect the slide bushings and cam plate Replace any components that found to be worn excessively or appears abnormal 13 Note direction of roller thrust surface wid...

Page 178: ...ply any lubricants to the components Apply Loctite 242 Blue to threads and torque the retaining nut to 185 ft lbs 250 Nm IMPORTANT Be sure splines of cam plate are fully engaged on shaft spline before tightening the nut CVT SYSTEM DRIVEN CLUTCH SERVICE 1 Remove retaining bolt 2 Pull the clutch off the shaft using flywheel puller as shown 3 Remove the puller and place the driven clutch spring side ...

Page 179: ...ting the components 12 Carefully inspect the roller tracks in the hub of the moveable sheave Replace clutch assembly if tracks are visibly worn 13 Check the pin holes in the shaft of the fixed sheave Pins should be a firm fit in the holes 14 Inspect sheaves for wear damage or rough spots Replace the clutch assembly if sheaves are worn or damaged 15 Apply a light film of moly grease to seal lips an...

Page 180: ...2 Clean the threads of the shaft and threads of the spring retaining nut to remove all oil or grease 23 Place the driven clutch assembly in the compressor tool 24 Install spring 25 Install spring retainer on spring visually aligning the flats of the retainer with the flats on the threaded shaft 26 Install tool PA 47457 3 27 Retainer Alignment Tool onto spring retainer 28 Compress the clutch spring...

Page 181: ...8 13 CVT TRANSMISSION TRANSMISSION 18 ft lbs 24 5 Nm ...

Page 182: ...flector from right case Note orientation for installation later 5 Remove gear position switch and shift bell crank 6 Remove input shaft counter shaft and shift drum as an assembly 7 Clean all parts Remove seals from gear case and install new using an appropriate size seal driver 8 Inspect all bearings gear teeth and splines for wear or damage Inspect gear dogs carefully and replace if the edge of ...

Page 183: ...t shift fork for bending and the surface for wear burning or scoring 12 Inspect the shift fork shaft and all springs Inspect detent cam and pawl for wear 13 Reassemble the drum starting with shaft guide detent cam wide flange faces toward the threaded end of drum the flat washer and snap ring 14 Place fork shaft through guide with pointed end as shown Inspect Shift Fork ...

Page 184: ...port faces away from the fork 16 Install the detent ratchet with spring Install the snap ring 17 Assemble the shafts with chain and shift drum and install the assembly into the case 18 Install the output gear and oil deflector Lubricate all components Spring Collar Large Spring Fork Small Spring Shaft Support Shaft Support DOT Oil Deflector Output Gear ...

Page 185: ...tall bolts and torque in two steps following a cross pattern to 18 ft lbs 24 5 Nm 22 Install the shift arm bell crank 23 Rotate the shafts to be sure they turn smoothly Verify shifting through all gears while rotating the shafts 24 Verify drain plug is tight 18 ft lbs 24 5 Nm Fill transmission with specified type and quantity Refer to Maintenance Section for procedure ...

Page 186: ...NOTES CVT TRANSMISSION 8 18 ...

Page 187: ...K EVEN TEST 9 17 ALTERNATOR OUTPUT TEST AC AMP 9 18 BATTERY IDENTIFICATION 9 18 CONVENTIONAL BATTERY ACTIVATION SVC 9 19 BATTERY TERMINALS TERMINAL BOLTS 9 19 CONVENTIONAL BATTERY INSPECTION REMOVAL 9 20 CONVENTIONAL BATTERY INSTALLATION 9 20 CONVENTIONAL BATTERY TESTING 9 20 CONVENTIONAL BATTERY OCV OPEN CIRCUIT VOLTAGE TEST 9 20 CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST 9 21 CONVENTIONAL BATTER...

Page 188: ...e 77 Digital Multimeter PV 43568 This meter is acceptable for use when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply FUSE SPLICE SAVER The fuse splice save...

Page 189: ...ound RPM LIMIT MODES Engine RPM is limited when Operator selects reverse gear The maximum vehicle speed when reverse gear is selected is 6 5 MPH If the wheel speed sensor malfunctions the speedometer will limit engine RPM to approximately 3500 RPM when the transmission is in reverse Maximum engine RPM is reached The reverse engine RPM limit can be overridden when the operator presses and holds the...

Page 190: ...ngine RPM from the Y RED AC signal from the voltage regulator The gauge is powered by switched R BLK and switched R WHT battery voltage Both the key and the RUN switches have to be closed to power up the gauge The gear selector switch provides a ground path for the FWD BLU RED or neutral GRN WHT circuits ...

Page 191: ...If voltage is not found inspect the wiring harness or replace the instrument gauge 3 If voltage is found test the BRN RED ground circuit Verify there is continuity between the circuit and chassis ground 4 If all circuits function remove the speed sensor from the transmission Verify the sensor is not damaged 5 Back probe the GRN RED and BRN RED wires with the connector still connected to the sensor...

Page 192: ...N OFF switch Battery voltage is supplied to the AWD coil when the operator turns the key switch to RUN moves the AWD switch to AWD and moves the RUN OFF switch to RUN The AWD coil ground circuit is supplied by the instrument gauge The speedometer will not allow the AWD to engage when the engine RPM is 3100 RPM or higher ...

Page 193: ...t the engine off The operator can override the RPM speed limit in reverse but not the ETC RPM limit by pressing and holding the reverse override button located on the left handlebar The reverse override button also serves as the mode switch button for the instrumentation gauge The mode button toggles between the several function the gauge performs To rule out engine RPM limiting caused by the CDI ...

Page 194: ...LECTRICAL Charging System The charging system consists of Stator Battery Regulator Rectifier The regulator rectifier is responsible for converting AC voltage to DC voltage and generating the tachometer pulse ...

Page 195: ...9 9 ELECTRICAL Ignition System The ignition system consists of CDI Controller Battery Ignition Coil Stator Pulse Coil ETC Key Run Off Switches Instrument Gauge ...

Page 196: ...9 10 ELECTRICAL Starting System The starting system consists of Battery Key Switch Run Off Switch Solenoid Brake Neutral Switches Diodes Starter Motor ...

Page 197: ...cuit is an indication that one of the three circuits may be weak or failed TEST 2 Stator Output 1 Place the red lead on the tester in the 10A jack 2 Turn the selector dial to the AC AMPs position 3 Start the engine and let it idle 1200 RPM 4 Separately test each leg of the stator by connecting the meter leads to the wires leading from the alternator W1 to W2 W1 to W3 W2 to W3 Alternator Current Ou...

Page 198: ...age tests to be performed accurately Follow the directions provided with the adaptor All measurements are indicated in Volts Readings obtained without a peak reading adaptor will be significantly different Disconnect the stator connectors from the CDI module Test output from the detection and pulse trigger coil and compare to the chart The following measurements were obtained when cranking the eng...

Page 199: ...A cable that is too tight will cause ETC interruption resulting in false engine RPM limiting IGNITION SYSTEM TESTING Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight Also be sure that colors match when wires are connected Use the following pages as a guide for troubleshooting The resistance values are also given on t...

Page 200: ... to ground 0 2 Ω Disconnect and check the secondary coil Resis tance values should be Primary Side Primary Wire Tab to Ground on coil mount or engine 21 Ohms Secondary Side High Tension Wire to engine ground Cap installed 8 200Ω Cap removed 3 200Ω Are these values within specs If all of the above tests are within specifications and all grounds connections and wire color coding have been inspected ...

Page 201: ...d or faulty Poor ignition coil ground e g corroded Faulty stator measure resistance of all ignition related windings Incorrect wiring inspect color coding in connectors etc Faulty ignition coil winding measure resistance of primary and secondary Worn magneto RH end Crankshaft bearings Sheared flywheel key Flywheel loose or damaged Excessive crankshaft runout on magneto RH end should not exceed 005...

Page 202: ...tery voltage must be present on red wire terminal on harness side of voltage regulator connector Is it If all of the previous tests indicate a good condition but the charging voltage does not rise above battery voltage at the connector or terminal board replace the voltage regulator Yes No No Yes Yes Remove the battery and properly ser vice Reinstall the fully charged battery or a fully charged sh...

Page 203: ...negative amps battery discharge Reverse meter leads if a positive reading is indicated Shift transmission into neutral and start the engine Turn headlight on and apply the brake light Increase engine RPM while observing ammeter and tachometer Note RPM at which the battery starts to charge ammeter indication is positive With lights and other electrical load off this should occur at approximately 15...

Page 204: ...different service procedures Proper servicing and upkeep of your battery is very important for maintaining long battery life Your ATV may have a Conventional Battery or a Sealed Low Maintenance Battery To identify which type of battery your ATV has refer to the illustration below and follow the correct service and charging procedures that follow in the manual CAUTION This test simulates a full loa...

Page 205: ... 10 of 14 amp battery 1 4 amp 1 10 of 18 amp battery 1 8 amp recommended charging rates 6 Check specific gravity of each cell with a hydrometer to assure each has a reading of 1 270 or higher BATTERY TERMINALS TERMINAL BOLTS Use Polaris corrosion resistant Nyogel grease PN 2871329 on battery bolts See Battery Installation WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious b...

Page 206: ...t tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion The vent tube should be routed away from frame and body to prevent contact with electrolyte Avoid skin contact with electrolyte as severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 5...

Page 207: ...oad test should be conducted whenever poor battery performance is encountered To perform this test hook a multitester to the battery in the same manner as was done in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 vol...

Page 208: ...y CONVENTIONAL BATTERY CHARGING PROCEDURE 1 Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Install battery in vehicle Coat threads of battery bolt with a corrosion resistant dielectric gre...

Page 209: ...d coil by connecting an ohmmeter between the coil leads Resistance should be 3 7Ω 1 Check solenoid ground path between the Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery to solenoid wire Depress starter button Reading should be less than 1 V D C Voltage Drop Testing See Page 9 22 for instructions Connect the black te...

Page 210: ...9 24 ELECTRICAL STARTER MOTOR EXPLODED VIEW BRUSH LENGTH SERVICE LIMIT 5 16 8 MM ...

Page 211: ...r motor gear Faulty flywheel gear or loose flywheel VOLTAGE DROP Testing 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 high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC per connection or component To per...

Page 212: ...nsulated brush and starter housing Reading should be 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 brush end frame off end of starter NOTE The electrical input post must stay with the field coil housing 4 Measure resistance between ground brush and ...

Page 213: ...ding should be infinite no continuity 5 Check commutator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replacement of the starter motor 6 Place armature in a growler Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1 8 3 cm above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole the armature is sh...

Page 214: ... and install shims 8 Align brush plate and install cover and screws 9 Lightly grease pinion shaft and install pinion spring stopper and snap ring 10 Install the starter onto the engine case Hand tighten each of the starter bolts Torque the bottom bolt first to 9 ft lbs 12 Nm Then torque the top bolt to the same specification NOTE It is important to tighten the bottom starter bolt first as the bott...

Page 215: ...r the overrun clutch and into the spring groove Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick out shoes 2 Remove the retaining ring thrust washer spring retainers and clutch return spring Screw the overrun clutch off the end of the pinion shaft Remove the old spring and install a new one Lightly grease the pinion shaft and reinstall th...

Page 216: ...NOTES ELECTRICAL 9 30 ...

Page 217: ...10 1 WIRE DIAGRAM 2006 HAWKEYE 2X4 4X4 ...

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