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Polaris 2007 Sportsman 450 EFI, Service Manual

The Polaris 2007 Sportsman 450 EFI Service Manual is a comprehensive guide for maintaining and repairing your ATV. Download this manual for free from manualshive.com to keep your vehicle in top condition. With step-by-step instructions and detailed diagrams, you can confidently tackle any maintenance tasks on your own.

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ELECTRICAL

10.1

CHAPTER 10

ELECTRICAL

10

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
IGNITION SYSTEM / BASIC ELECTRICAL COMPONENTS  . . . . . . . . . . . . . . . . . . . . 10.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

POWER DISTRIBUTION MODULES (PDM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.5

SPORTSMAN EFI OVERVIEW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
SPORTSMAN 450 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.13

OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
INSTRUMENT CLUSTER DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
SETTING A NEW SERVICE INTERVAL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
EFI DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
SPEEDOMETER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
SPEEDOMETER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18

ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING  . . . . . . . . . . . . . .  10.19

TEST 1 - NO ALL WHEEL DRIVE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
TEST 2 - NO SPEEDOMETER DISPLAY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
TEST 3 - NO REVERSE SPEED LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
TEST 4 - NO AWD HUB SAFETY LIMIT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
TEST 5 - REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR  . . . . . . . . 10.22
TEST 6 - WHEEL SPEED SENSOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
TEST 7 - FUEL GAUGE DISPLAY NOT WORKING  . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
TEST 8 - SHIFT INDICATOR NOT WORKING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23

ACTIVE DESCENT CONTROL (ADC) COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.24

OPERATION OVERVIEW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
DIAGNOSING SYSTEM FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24

ALL WHEEL DRIVE (AWD) COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.24

OPERATION OVERVIEW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
DIAGNOSING SYSTEM FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24

COOLING SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.25

FAN CONTROL CIRCUIT OPERATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
FAN CONTROL BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
FAN MOTOR CURRENT DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
COOLANT TEMPERATURE SENSOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26

GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.26

TEST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26

ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . .  10.27

OPERATION OVERVIEW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
ETC TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.28

OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
COMPONENTS OF EFI ALTERNATOR AND DC / CDI IGNITION SYSTEM . . . . . . . 10.29
EFI IGNITION SYSTEM TESTING FLOW CHART  . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CRANKSHAFT POSITION SENSOR GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
IGNITION TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
IGNITION OUTPUT TEST USING GAP TESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.32

CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
BREAK EVEN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
ALTERNATOR OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
CHARGING SYSTEM TESTING DIAGRAMS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34

DIFFERENTIAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10.36

TESTING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36

Summary of Contents for 2007 Sportsman 450 EFI

Page 1: ...ols Use only the proper tools as specified Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2007 Sportsman 45...

Page 2: ...E NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLO...

Page 3: ...1 GENERAL 2 MAINTENENCE 3 ENGINE 4 FUEL SYSTEM 5 BODY SUSPENSION 6 CLUTCH 7 TRANSMISSION 8 FINAL DRIVE 9 BRAKES 10 ELECTRICAL 11 INTERNATIONAL...

Page 4: ...NOTES...

Page 5: ...ND STANDARD MODEL COMPONENT COMPARISON 1 4 SPORTSMAN X2 DELUXE AND STANDARD MODEL COMPONENT COMPARISON1 5 2007 SPORTSMAN 450 1 6 MODEL NUMBER A07MH46AA AZ 1 6 2007 SPORTSMAN 500 EFI 1 8 MODEL NUMBER A...

Page 6: ...ber whenever corresponding about an engine This information can be found on the sticker applied to the top side of the crankcase A An additional number is stamped on the side of the crankcase beneath...

Page 7: ...Manual PN Parts Micro Fiche PN 2007 Sportsman 500 EFI A07MN50A Deluxe A07MH50A Standard A07MH50F Standard Intl 9920364 9920365 N A 2007 Sportsman X2 500 EFI A07TN50A Deluxe A07TH50A Standard 9920632 9...

Page 8: ...2 Titan Tires PVT w EBS 3 Non EBS X2 excluded Rear Work Lights 4 No Work Lights Front Drive w Active Descent Control ADC 5 No Active Descent Control ADC Speed Sensor Wiring for ADC 6 No Sensor Wiring...

Page 9: ...eluxe and Standard model were offered Use the following table as a guide X2 DELUXE MODEL Item Location X2 STANDARD MODEL Winch 1 No Winch Rear Work Lights 2 No Work Lights Front Drive w Active Descent...

Page 10: ...on Capacity Length 83 in 211 cm Width 48 in 122 cm Height 48 in 122 cm Wheel Base 50 5 in 128 3 cm Ground Clearance 11 in 27 94 cm Dry Weight 715 lbs 324 kg Gross Vehicle Weight 1210 lbs 549 kg Front...

Page 11: ...Circuit Protection Solid State PDM Starting Electric Recoil Instrument Cluster Analog Speedo w LCD Table 1 6 Sportsman 450 Drivetrain Transmission Type Drumshift H L N R P Transmission Capacity 32 oz...

Page 12: ...General Specifications Category Dimension Capacity Length 83 in 211 cm Width 48 in 122 cm Height 48 in 122 cm Wheel Base 50 5 in 128 3 cm Ground Clearance 11 25 in 28 6 cm Dry Weight 715 lbs 324 kg G...

Page 13: ...amp Switched Power 10 amp Fuel Pump 10 amp ECU 15 amp Ignition Coil 10 amp Accessory Power 10 amp Lights 20 Amp Starting Electric Recoil Instrument Cluster Analog Speedo w LCD Table 1 11 Sportsman 500...

Page 14: ...ategory Dimension Capacity Length 93 in 236 cm Width 48 in 122 cm Height 48 in 122 cm Wheel Base 57 in 145 cm Ground Clearance 11 in 28 cm Dry Weight 798 lbs 362 kg Gross Vehicle Weight 1500 lbs 680 k...

Page 15: ...Hr Circuit Breakers Fan 12 amp Switched Power 10 amp Fuel Pump 10 amp ECU 15 amp Ignition Coil 10 amp Accessory Power 10 amp Lights 20 Amp Starting Electric Recoil Instrument Cluster Analog Speedo w L...

Page 16: ...fications The following torque specifications are to be used as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views in each manual se...

Page 17: ...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...

Page 18: ...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 Li...

Page 19: ...r 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 Magnetic Induction As a conductor...

Page 20: ...NOTES GENERAL INFORMATION 1 16...

Page 21: ...L FILTER 2 17 COMPRESSION TEST 2 17 ENGINE MOUNTS 2 17 SPARK PLUG 2 18 ACTIVE DESCENT CONTROL ADC RESERVOIR LEVEL 2 18 BATTERY MAINTENANCE 2 18 LIQUID COOLING SYSTEM OVERVIEW 2 19 COOLANT STRENGTH TYP...

Page 22: ...ON 2 31 CV SHAFT BOOT INSPECTION 2 31 CONTROLS 2 31 WHEELS 2 31 WHEEL HUB AND SPINDLE TORQUE TABLE 2 32 WHEEL REMOVAL FRONT OR REAR 2 32 WHEEL INSTALLATION 2 32 TIRE PRESSURE 2 32 TIRE INSPECTION 2 33...

Page 23: ...f the 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...

Page 24: ...Pre Ride Verify Box is latched E Air filter pre filter Daily Inspect clean often E Air box sediment tube Daily Drain deposits when visible Coolant Daily Check level daily change coolant every 2 years...

Page 25: ...M 310 500 Inspect lubricate adjust Steering 50 H 6 M 310 500 Lubricate Front suspension 50 H 6 M 310 500 Lubricate Rear suspension 50 H 6 M 310 500 Lubricate E Throttle Cable ETC Switch 50 H 6 M 310...

Page 26: ...ses if applicable 100 H 12M 620 1000 Inspect for leaks Engine mounts 100 H 12M 620 1000 Inspect Exhaust muffler pipe 100 H 12M 620 1000 Inspect E Spark plug 100 H 12M 620 1000 Inspect replace as neede...

Page 27: ...2 7 MAINTENANCE 2 LUBRICATION FLUIDS SPORTSMAN Component Locations Sportsman Only Deluxe...

Page 28: ...ntrol Run Switch Speedometer Override Rear Dump Box Passenger Area PVT Cover Oil Dipstick Front Demand Behind Radiator Front Storage Compartment Rack Gas Cap Gear Shifter Front Drive CV Shafts Front P...

Page 29: ...mium All Season Grease 3 oz cartridge 24 count 2871423 Premium All Season Grease 14 oz cartridge 10 count 2871460 Starter Drive Grease 12 count 2871515 PremiumU JointLube 3 oz 24 Count 2871551 Premium...

Page 30: ...t Taillight Brakelight check operation of all indicator lights and switches Engine stop switch check for proper function Wheels check for loose wheel nuts and axle nuts check to be sure axle nuts are...

Page 31: ...urs in extremely dirty conditions or short trip cold weather operation 2 Transmission Polaris AGL Synthetic Gearcase Lube Add lube to bottom fill hole Change annually o 3A 3B Front Gearcase ADC Fluid...

Page 32: ...ubricant 1 Remove gearcase drain plug A located on the bottom of the gearcase and drain oil The drain plug is accessible through the skid plate Catch and discard used oil properly 2 Clean and reinstal...

Page 33: ...n oil drain plug area 2 Clean around the drain plug and remove the drain plug and wipe the magnetic end clean to remove all accumulated metallic filings 3 After the oil has drained completely install...

Page 34: ...to loosen Loosen bleeder screw slowly allowing oil and any trapped air to flow out of fitting IMPORTANT Do not allow hydraulic fluid in reservoir to drain below minimum fill line Close bleeder valve...

Page 35: ...snap 3 Repeat procedure at the other five locations as shown NOTE Do not attempt to remove cover until all latch points are released Throttle Cable Electronic Throttle Control ETC Switch Adjustment 1...

Page 36: ...or signs of wear deterioration damage or leakage Replace every two years Be sure vent lines are routed properly and secured with cable ties WARNING Gasoline is extremely flammable and explosive under...

Page 37: ...n test Smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Abnormally high compression can be caused by a decompre...

Page 38: ...Polaris ADC fluid when required Battery Maintenance Complete battery servicing information for both conventinoal and sealed batteries can be found in Chapter 10 of this manual NOTE Expected battery sh...

Page 39: ...ating of engine could occur if air is not fully purged from system Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water Coolant Strength Type Test the strength of the co...

Page 40: ...e and or repair However if the recovery bottle has run dry or if overheating is evident the level in the radiator should be inspected and coolant added if necessary NOTE Use of a non standard pressure...

Page 41: ...the assembly and tighten NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling NOTE The air filter should rest on the filter support Proper placem...

Page 42: ...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 screw once housing has been drained CAUTION Ma...

Page 43: ...icate moisture collecting in the oil reservoir If the oil level is over the full mark change the oil Oil and Filter Change NOTICE Care must be taken to ensure that the fluids are contained Be prepared...

Page 44: ...Place shop towels beneath oil filter Use Oil Filter Wrench PV 43527 turn filter counterclockwise to remove 16 Using a clean dry cloth clean filter sealing surface on the crankcase 17 Lubricate the o r...

Page 45: ...positioned at Top Dead Center TDC on compression stroke 1 Remove the seat 2 Remove body panels and fuel tank as necessary to gain access to valve cover 3 Remove the spark plug high tension lead and re...

Page 46: ...the engines valves NOTE Both feeler gauges should remain inserted during adjustment of each valve 3 When clearance is correct hold adjuster screw and tighten locknut securely 4 Re check the valve cle...

Page 47: ...andlebars in this position NOTE The steering arm center section can be used as an indicator of whether the handlebars are straight The center section should always point straight back from the steerin...

Page 48: ...ission in Park and start the engine Purge accumulated carbon from the system by momentarily revving the engine several times CAUTION During tie rod adjustment it is very important that the following p...

Page 49: ...e the machine is in Park and repeat Steps 2 and 3 SEE WARNING 6 Repeat steps 2 through 5 until no more particles are expelled when the engine is revved 7 Stop the engine and allow the arrestor to cool...

Page 50: ...raulic auxiliary foot brake system and adjust or bleed if necessary First check foot brake effectiveness by applying 50 lb approx downward force on the pedal The top of the pedal should be at least 1...

Page 51: ...ntrols Check controls for proper operation positioning and adjustment Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body...

Page 52: ...ground 4 Securely tighten the wheel nuts to the proper torque listed in the table Tire Pressure Item Specification Steel Front Wheel Nuts 27 Ft Lbs 37 Nm Steel Rear Wheel Nuts 27 Ft Lbs 37Nm Aluminum...

Page 53: ...ins are in place Refer to specific fastener torques listed in each chapter Storage Compartments The storage compartments are easily accessible To open the front compartment turn the latch handle to th...

Page 54: ...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 IN or relea...

Page 55: ...ow crimp cover is located in the rear fender area The red wire connects to the battery The Orange White wires are located under the front cover under headlight pod The Orange White wires supply the co...

Page 56: ...uel in the tank and EFI sytem carburetor Turn the fuel valve off and drain the carburetor bowl 450 only Oil and Filter Warm the engine and change the oil and filter Follow the procedure in this chapte...

Page 57: ...ions Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure and safely support the ATV with the ti...

Page 58: ...2 38 MAINTENANCE Maintenance Schedule Service Date Hours Miles Service Performed Serviced By...

Page 59: ...KER ARM CAMSHAFT REMOVAL 3 14 CAM CHAIN TENSIONER INSPECTION 3 14 ROCKER ARM SHAFT INSPECTION 3 15 CAMSHAFT REMOVAL 3 16 AUTOMATIC COMPRESSION RELEASE REMOVAL INSPECTION 3 17 AUTOMATIC COMPRESSION REL...

Page 60: ...3 40 CRANKCASE ASSEMBLY 3 41 WATER PUMP MECHANICAL SEAL INSTALLATION 3 41 WATER PUMP MECHANICAL SEAL REMOVAL ENGINE INSTALLED 3 41 ONE WAY VALVE INSTALLATION 3 42 CAM CHAIN DRIVE SPROCKET INSTALLATIO...

Page 61: ...2mm 11 15 15 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm Oil Filter Pipe Fitting 20mm 36 43 49 59 Nm Oil Hose Fitting 1 8 Pipe Thread 6 5 11 9 15 Nm Hard Metal Oil Line Banjo Fitting N A 11 16...

Page 62: ...8 005 38 025 mm Camshaft Oil clearance Std 022 0035 055 090 mm Limit 0039 10 mm Cylinder Head Surface warpage limit 0020 05 mm Standard Height 3 870 98 3 mm Valve Seat Contacting width In Std 028 7 mm...

Page 63: ...9053 9055 22 994 23 0 mm Standard clearance piston pin to pin bore 0002 0003 004 008 mm Degree of fit Piston Pin must be a push by hand fit at68o F 20o Piston Ring Piston Ring Installed gap Top ring S...

Page 64: ...ine The other numbers are used for identification as to diameter length and design Four stroke engine rings are rectangular profile See text for oil control ring upper rail installation Use the inform...

Page 65: ...cooling system hoses and clamps or water pump seal Radiator Cap Pressure Test 1 Remove radiator cap and test using a cap tester commercially available 2 The radiator cap relief pressure is 13 lbs 89...

Page 66: ...r Front Cab Refer to Chapter 5 Fuel Tank Refer to Chapter 4 5 Disconnect spark plug high tension lead 6 Remove springs from exhaust pipe and remove pipe 7 Drain coolant and engine oil 8 Remove air pre...

Page 67: ...In Period 4 Cycle Engine Break In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel 1 Use only Polaris Premium 4 All Season synthetic oil or API certified SH oil Neve...

Page 68: ...to the corners of the intake and exhaust ports Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylind...

Page 69: ...l is diverted in two directions Oil is supplied to the camshaft through the left front cylinder stud and an oil passage in the head Oil enters the camshaft through the PTO L journal The camshaft journ...

Page 70: ...Oil Pump Scavenging Oil Hose Oil Strainer Crankcase Oil Gallery Oil Pump Feed One Way Valve Bypass Oil Filter Delivery Pipe Crankshaft Prevents oil from draining into crankcase with engine off Top of...

Page 71: ...3 13 ENGINE 3 EH50PL Engine Exploded Views Crankshaft Cylinder and Piston Cylinder Head Crankcase Valvetrain...

Page 72: ...on hole and the cam sprocket pin facing upward aligned with the camshaft to crankshaft center line NOTE The cam lobe should be pointing down and valves should have clearance at this point 5 Remove cam...

Page 73: ...ner assembly if any part is worn or damaged Rocker Arm Shaft Inspection 1 Mark or tag rocker arms to keep them in order for assembly 2 Inspect each rocker arm cam follower surface If there is any dama...

Page 74: ...or damaged parts NOTE The end of the adjuster screw is hardened and cannot be ground or re faced Camshaft Removal 1 Remove thermostat housing 2 Remove camshaft sprocket inspection cover 3 Loosen three...

Page 75: ...s not replaceable Replace the camshaft as an assembly if the actuator ball is worn or damaged 1 Check release lever shaft A for smooth operation throughout the entire range of rotation The spring B sh...

Page 76: ...ttom of illustration at right 6 Place arm of spring under stop pin as shown and push release lever inward until fully seated Do not pre wind the spring one full turn or the compression release will no...

Page 77: ...emoval 1 Remove the two 6mm flange bolts A from cylinder head See next exploded view on next page 2 Loosen each of the four cylinder head bolts B evenly 1 8 turn each time in a criss cross pattern unt...

Page 78: ...3 20 ENGINE Cylinder Head Exploded View EH50PL EH50PL A...

Page 79: ...in order with respect to their location in the cylinder head 1 Using a valve spring compressor A compress the valve springs and remove the split keeper NOTE To prevent loss of tension do not compress...

Page 80: ...TE The valves cannot be re faced or end ground Valves must be replaced if worn bent or damaged 5 Measure diameter of valve stem with a micrometer in three places and in two different directions six me...

Page 81: ...valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circu...

Page 82: ...ce 46o cutter on the pilot and make a light cut 10 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 cu...

Page 83: ...all filings from the area with hot soapy water rinse and dry with compressed air 15 Lubricate the valve guides with clean engine oil and apply oil or water based lapping compound to the face of the va...

Page 84: ...Clean and dry the combustion chamber area 2 Pour a small amount of clean high flash point solvent into the intake port and check for leakage around each intake valve The valve seats should hold fluid...

Page 85: ...e clamps and remove coolant inlet hose 4 Remove the two 6 mm cylinder base bolts 5 Loosen each of the four large cylinder base bolts 1 4 turn at a time in a criss cross pattern until loose and remove...

Page 86: ...second 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 which fits into a notch A in...

Page 87: ...diameter at a point 40 mm down from the top of the piston at a right angle to the direction of the piston pin 2 Subtract this measurement from the maximum cylinder measurement obtained in Step 5 abov...

Page 88: ...place the rings If ring gap is below specified limit file ring ends until gap is within specified range NOTE Always check piston ring installed gap after re boring a cylinder or when installing new ri...

Page 89: ...rance exceeds the service limit 6 Inspect gear teeth on starter drive Replace starter drive if gear teeth are cracked worn or broken Flywheel Stator Removal Inspection 1 Remove flywheel nut and washer...

Page 90: ...chain drive sprocket and woodruff key from crankshaft 6 Inspect sprocket teeth for wear or damage 7 Inspect woodruff key for wear 8 Replace any worn or damaged parts One Way Valve Removal The one way...

Page 91: ...parate the crankcase 4 Remove the Mag RH crankcase from the PTO case Oil Pump Removal Inspection 1 Remove pump shaft bearing A and thrust washer B from pump shaft 2 Remove 2 bolts holding pump drive g...

Page 92: ...ecome plugged 2 Install pump shaft and scavenge rotor drive pin 3 Install outer scavenge rotor inner scavenge rotor and scavenge casing 4 Install outer feed rotor and inner feed rotor drive pin 5 Inst...

Page 93: ...case The inner race should be firm with minimal side to side movement and no detectable up and down movement Crankshaft Removal Inspection 7 Remove the shim washer A from the crankshaft 8 Support the...

Page 94: ...e removal process and should not be re used Pump Shaft Oil Seal Water Pump Mechanical Seal Removal Engine Disassembled NOTE The water pump mechanical seal can be removed without removing the engine Re...

Page 95: ...performed to determine the amount of crankshaft counter balancer shaft and pump shaft end play Excessive end play may cause engine noise at idle and slow speeds Too little play will side load the bea...

Page 96: ...r dial caliper and record Crankshaft Width____________ 10 Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6 and record below Total End Play_____________ 11...

Page 97: ...ne if a different shim is needed The result must be within the specified range listed at below Oil Pump Shaft End Play Adjustment 1 Make sure the pump shaft bearing is firmly seated in the Magneto sid...

Page 98: ...shaft and tighten the nut to draw the crankshaft into the main bearings until fully seated Loosen the nut and remove the threaded rod from the crankshaft If removal is difficult install two nuts on th...

Page 99: ...the pump shaft 7 Screw the guide onto the end of the pump shaft 8 Install the washer and nut and tighten to draw seal into place until fully seated 9 Remove the guide adaptor using the additional nut...

Page 100: ...echanical seal Ill 5 6 Turn the puller T Handle clockwise until it contacts the water pump shaft Continue rotating until the remaining portion of mechanical seal has been removed from the cases Ill 6...

Page 101: ...marking and can be installed either way The ends should butt squarely together and must not overlap 2 Install the oil ring top rail NOTE The top rail has a locating tab to prevent rotation The tab mus...

Page 102: ...ang outward See Caution with Step 3 above Push the piston pin in both directions to make sure the clips are properly seated in the groove Cylinder Installation 7 Place the dowel pins in the crankcase...

Page 103: ...d cylinder Remove all traces of old gasket material Refer to disassembly photos 1 Install the cam chain tensioner guide Be sure bottom end of guide is located properly in crankcase 2 Install the two d...

Page 104: ...rom the cam chain and rotate the engine to align the single TDC timing mark Top Dead Center on the flywheel with the notch in the timing inspection window Be sure to use the single TDC mark when insta...

Page 105: ...crankshaft to camshaft centerline Refer to illustration 8 Apply Crankcase Sealant PN 2871557 to the camshaft end cap and install using a new O Ring 9 Check all cam timing marks to verify proper cam ti...

Page 106: ...3 48 ENGINE CAMSHAFT TIMING Dots Crankshaft to Camshaft Centreline Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks...

Page 107: ...new O Ring in the oil passage recess in the crankcase 3 Apply 3 Bond 1215 PN 2871557 or an equivalent sealer to the stator plate outer surface and install a new O Ring 4 Install the stator plate bein...

Page 108: ...il to the threads of the bolts and tighten evenly 7 Adjust valves according to the valve adjustment procedure found in Chapter 2 Maintenance 8 Apply clean engine oil liberally to the valve springs cam...

Page 109: ...spring and inspect Replace spring or ratchet pawl if worn broken or damaged NOTE Long arm of spring engages reel Short end against pawl 7 Hold reel firmly in housing Pull rope handle until 12 18 30 4...

Page 110: ...o the center post of the housing and the bushing 5 Install reel into housing making sure the spring drive tab on the reel engages the spring and the reel is fully seated in the housing 6 Apply downwar...

Page 111: ...intake system Restricted engine breather system Oil contaminated with fuel Restricted oil tank vent Engine Engine Turns Over But Fails to Start No fuel Dirt in fuel line or filter Fuel will not pass...

Page 112: ...r incorrect plug or plug gap Carburetion faulty lean condition Exhaust system air leaks Ignition system faulty Spark plug cap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty...

Page 113: ...FUEL SYSTEM 4 1 CHAPTER 4 FUEL SYSTEM 4 ELECTRONIC FUEL INJECTION 4 3 4 30 CARBURETOR SPORTSMAN 450 4 31 4 47...

Page 114: ...4 2 FUEL SYSTEM...

Page 115: ...ENT 4 14 FUEL PRESSURE REGULATOR 4 15 GENERAL INFORMATION 4 15 FUEL FILTERS 4 16 GENERAL INFORMATION 4 16 FUEL INJECTOR 4 16 GENERAL INFORMATION 4 16 CRANKSHAFT POSITION SENSOR CPS 4 17 GENERAL INFORM...

Page 116: ...6 EFI CIRCUIT POWER ON 4 26 EFI CIRCUIT CRANK POSITION SENSOR 4 26 EFI CIRCUIT FUEL PUMP 4 27 EFI CIRCUIT IGNITION COIL 4 27 EFI CIRCUIT IDLE AIR CONTROL 4 28 EFI CIRCUIT THROTTLE POSITION SENSOR 4 28...

Page 117: ...ure Test Valve Kit 2201519 Throttle Position Sensor Tester PU 47471 Digital Wrench SmartLink Kit WARNING Gasoline is extremely flammable and explosive under certain conditions EFI components are under...

Page 118: ...l Wrench diagnostic software Polaris dealers can also order separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 For use on all 15 pin connector based...

Page 119: ...omponents Do not use dielectric grease on sealed connectors connectors with a rubber grommet as it may displace the rubber seal and allow contaminants to enter the connector Never attempt to service a...

Page 120: ...3 Intake Air Temperature Sensor IAT 4 Idle Air Control IAC 5 Crankshaft Position Sensor CPS inside cover 6 Fuel Injector 7 Fuel Rail 8 Fuel Filter s 9 Fuel Pump Tank Assy 10 Engine Coolant Temperatur...

Page 121: ...r Control IAC 5 Crankshaft Position Sensor CPS inside recoil cover 6 Fuel Injector 7 Fuel Rail 8 Fuel Filters 1 located in tank 1 under front cab 9 Fuel Pump Regulator Gauge Sender Assembly located In...

Page 122: ...s fed through the fuel rail and into the injector which injects into the intake port The ECM controls the amount of fuel by varying the length of time that the injectors are on This can range from 1 5...

Page 123: ...engine If the engine fails to start a problem may still exist and should be diagnosed NOTE Accurate testing of EFI components is recommended utilizing the Polaris Diagnostic Software dealer only FUEL...

Page 124: ...into the ECM If the maximum RPM limit 7000 is exceeded the ECM will suppress the ignition signal or injection signal This process repeats itself in rapid succession limiting operation to the preset m...

Page 125: ...o be faulty If a fuel delivery problem is suspected make certain the filters are not plugged that the pump is being activated through the ECM all electrical connections are properly secured the fuses...

Page 126: ...ation by plugging in a known good ECM NOTE If the pump still does not operate replace the pump tank assembly Fuel Pump Tank Assembly Replacement NOTE All EFI units utilize quick connect fuel lines NOT...

Page 127: ...tion The fuel pressure regulator maintains the required operating system pressure of 39 psi 3psi A rubber fiber diaphragm divides the regulator into two separate sections the fuel chamber and the pres...

Page 128: ...ant the ECM completes the ground circuit energizing the injector The valve needle in the injector is opened electromagnetically and the pressure in the fuel rail forces fuel down through the inside Th...

Page 129: ...aid installation The lower O ring should remain dry Torque the fuel rail mounting screws to 5 7 ft lbs 6 9 Nm Then install the doubler plate and torque to 8 9 5 ft lbs 11 13 Nm CRANKSHAFT POSITION SE...

Page 130: ...s the ECM to adjust the fueling according to actual engine load as well as identify which stroke is the intake stroke The MAP sensor also provides the ECM with the ability to compensate for high altit...

Page 131: ...w sensor using a twisting motion to properly seat the sensor in the grommet 4 Re connect the harness IDLE AIR CONTROL IAC General Information The Idle Air Control IAC is used to stabilize the idle qua...

Page 132: ...set to the ohms scale observe the reading at the following pin locations of the TPS Using TPS Test Adapter Harness 2201519 Set up the TPS Test Harness 2201519 according to the instructions Verify that...

Page 133: ...S setting This step is crucial as it sets the TPS position using the fixed physical stop Open and close throttle plate a couple of times to ensure full throttle closing Do not snap closed as this coul...

Page 134: ...for any reason the engine temperature sensor circuit is interrupted the fan will default to ON Engine Temperature Sensor Test Polaris dealers can test the sensor by using the Polaris Digital Wrench S...

Page 135: ...Sensor or disconnected wiring Throttle stop screw tampering replace throttle body POOR IDLE Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw tampering replace th...

Page 136: ...will appear on the LCD display and the Malfunction Indicator Light MIL or Check Engine light will begin to flash Read and record the number of flashes of the MIL light A code 12 indicates the beginnin...

Page 137: ...igh Voltage Yes 44 CPS Circuit Fault Yes 45 Barometric Pressure Sensor MAP Circuit Low Input Yes 46 Barometric Pressure Sensor MAP Circuit High Input Yes 47 IAC Open Load Yes 47 IAC Short to Ground Ye...

Page 138: ...4 26 FUEL INJECTION TROUBLESHOOTING DIAGRAMS EFI CIRCUIT Power On EFI CIRCUIT Crank Position Sensor...

Page 139: ...4 27 FUEL INJECTION 4 EFI CIRCUIT Fuel Pump EFI CIRCUIT Ignition Coil...

Page 140: ...4 28 FUEL INJECTION EFI CIRCUIT Idle Air Control EFI CIRCUIT Throttle Position Sensor...

Page 141: ...4 29 FUEL INJECTION 4 EFI CIRCUIT Manifold Absolute Pressure Sensor EFI CIRCUIT Engine Coolant Temperature...

Page 142: ...4 30 FUEL INJECTION EFI CIRCUIT Air Temperature Sensor EFI CIRCUIT Malfunction Indicator Light...

Page 143: ...4 37 FLOAT SYSTEM 4 37 PILOT SCREW 4 38 AIR FUEL MIXTURE RATIO 4 38 JET NEEDLE 4 39 NEEDLE JET 4 39 THROTTLE OPENING VS FUEL FLOW 4 39 CARBURETOR DISASSEMBLY MIKUNI CV 4 39 CARBURETOR CLEANING 4 40 C...

Page 144: ...tment Tool WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well ventilated area Do not overfill the tank The tank is a...

Page 145: ...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 Enrichm...

Page 146: ...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...

Page 147: ...n the venturi and therefore in the chamber above the diaphragm becomes significantly lower than atmospheric Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward raising...

Page 148: ...the float chamber The mixture rich in fuel content reaches starter plunger and mixes again with the air coming through a passage 8 extending from underneath the diaphragm The rich fuel air mixture for...

Page 149: ...w 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 ne...

Page 150: ...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 cl...

Page 151: ...y 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 t...

Page 152: ...t be removed Even a small amount of residue will reduce the flow characteristics of the jet 4 Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages...

Page 153: ...ested after assembly Carburetor Assembly Inspect the diaphragm A for holes deterioration or damage Make sure the diaphragm is pliable but not swollen The diaphragm should fit properly in the carbureto...

Page 154: ...pressing the needle valve pin 3 Measure the height from the float bowl mating surface to the top of step of the float as shown in Illustration 2 Both sides of float should be parallel to each other Th...

Page 155: ...or shut off however engine must run briefly to allow fuel level to stabilize 1 Attach a clear line to drain fitting Be sure line fits tightly on fitting Position hose along side of carburetor as shown...

Page 156: ...4 44 CARBURETOR SPORTSMAN 450 FUEL TANK FUEL DELIVERY SYSTEM Fuel System Exploded View...

Page 157: ...fitting on the pump 4 Apply 5 inches Hg vacuum to the pump fitting The diaphragm should hold vacuum indefinitely If fuel is present in the impulse line or vacuum chamber of the pump the diaphragm is...

Page 158: ...ssembly Tighten all screws evenly Fuel Filter Replacement 1 Loosen the filter clamps and remove filter 2 Install new filter onto fuel lines and install clamps FUEL GAUGE SENDING UNIT Sending Unit Remo...

Page 159: ...ow power spark plug erosion engine runs hot surging high idle idle speed erratic No fuel in tank Restricted tank vent or routed improperly Fuel lines or fuel valve restricted Fuel filter plugged Carbu...

Page 160: ...et incorrectly Idle mixture screw misadjusted or damaged Belt dragging Ignition timing incorrect Worn jet needle needle jet Plugged or restricted idle jet Erratic Idle Choke cable bending or incorrect...

Page 161: ...11 RADIATOR SCREEN REMOVAL 5 11 SPORTSMAN BODY ASSEMBLY EXPLODED VIEW 5 12 X2 BODY ASSEMBLY EXPLODED VIEW 5 13 BODY RACK EXPLODED VIEWS 5 14 HEADLIGHT POD EXPLODED VIEW 5 15 STEERING 5 16 HANDLEBAR B...

Page 162: ...Block 11 13 15 18 Master Cylinder Clamp Bolt 45 55 5 2 6 3 Rear Shock Bolt Upper 30 41 Rear Shock Bolt Lower 30 41 Rear Wheel Hub Nut 80 108 Upper Stabilizer Support Nuts 17 27 Upper Control Arm Moun...

Page 163: ...p on the insert DO NOT apply too much pressure on the side cutters or damage to the insert will occur 2 Next use the diagonal side cutters under outside insert B to completely remove the assembly NOTE...

Page 164: ...ward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it from the ATV 3 Reinstall the side panel by reversing the removal procedure Front Cover Removal Insta...

Page 165: ...res to install the foot well Be sure to properly align the cab ends into the foot wells upon reassembly X2 Foot Well Removal Installation 1 Remove the four plastic inserts A that secure the wheel well...

Page 166: ...move the four bolts that secure the storage rack to the frame 3 Remove the two T25 screws that secure the storage box to the front fender well areas each side 4 Remove the two T25 screws that secure t...

Page 167: ...up on the cover piece To install the front cover place top lip of the cover into and lift up to remove 6 Remove the front headlights C or simply disconnect the electric connector D before removing the...

Page 168: ...area of the cab if removed 6 Install the two plastic inserts E into the front cab if removed 7 Torque all bolts and screws according to the illustration 8 Install the front radiator cap cover E Sports...

Page 169: ...wo screws B that secure the front cab to the frame in the fuel tank mount area 4 Remove the side panels D refer to the SIDE PANEL REMOVAL section 5 Remove the plastic inserts E that secure the front o...

Page 170: ...ulling the locks on each side and removing the connectors Lift the rear cab from the frame 5 Reverse the removal steps for installation X2 Rear Quarter Panel Removal Installation 1 Remove the seat 2 R...

Page 171: ...r storage compartment in place 3 For installation reverse the removal steps 4 Torque the three T 25 screws that hold the rear storage to the rear cab to specification Radiator Screen Removal 1 Pull ou...

Page 172: ...embly Exploded View Rear Cab Assembly Pull UP on rear of seat and back to disengage tabs at front of seat Seat Latch Rear Cab Storage Frame Wheelwell Frame Front Brush Guard Support Side Cover Splash...

Page 173: ...EERING SUSPENSION 5 X2 Body Assembly Exploded View Rear Cab Assembly Frame Front Brush Guard Support Side Cover Splash Shields Front Cab Front Cover Front Cab Assembly Footwell Frame RH Rear Cab Footw...

Page 174: ...STEERING SUSPENSION Body Rack Exploded Views Rack Rails Rear Rack Rear Rack Support Frame Front Brush Guard Radiator Shield Radiator Screen Grill Front Bumper Panel Rack Rails Box Assembly Cover Sport...

Page 175: ...d E Assembly Install bottom of pod onto handlebar and secure to brackets Install key switch choke cable and headlight Connect 12Vdc power outlet where applicable Connect headlight Connect instrument c...

Page 176: ...h the middle hole B in the bottom block for proper installation The pin A and middle hole B should face the front of the ATV 4 Install the pin side bolts first and evenly tighten the bolts down Evenly...

Page 177: ...od end bolts A point down Verify inner rod ends are placed between the steering post arms Apply Loctite 242 to bolt threads 8 ft lbs 11 Nm 25 ft lbs 35 Nm 2 2 2 Always use new cotter pins upon reassem...

Page 178: ...to specification 9 Attach A arm to hub strut assembly Tighten ball joint nut to specification If cotter pin holes are not aligned tighten nut slightly to align Install a new cotter pin with open ends...

Page 179: ...urn nut I clockwise until ball joint is removed from strut housing 13 To install a new ball joint Remove extension cap and attach puller guide using short bolts provided in the kit 14 Remove extension...

Page 180: ...nd easily from full left to full right without binding SUSPENSION Front Strut Cartridge Replacement NOTE Refer to illustration on following page 1 Hold strut rod and remove top nut 2 Remove upper stru...

Page 181: ...t Assembly Nut 15 ft lbs 21 Nm Washer Spacer Rubber Upper Pivot Ball Spacer Nut Lower Pivot Ball Spring Retainer Spring Strut Bumper Strut Washer Bolts Hubstrut Bearing Retaining Ring Brake Caliper 18...

Page 182: ...ssembly 17 ft lbs 24 Nm Stabilizer Bar 35 ft lbs 48 Nm 30 ft lbs 41 Nm Rear Shock Lower Control Arm Bushings 35 ft lbs 48 Nm Upper Control Arm 30 ft lbs 41 Nm Rear Front 1 Orientate Bushings Correctly...

Page 183: ...ION 5 X2 Rear Suspension Exploded View Upper Control Arm Lower Control Arm Rear Shock Bushings Rear Compression Spring Preload Adjustment Cam A Arm Shaft Wheel Bearing Carrier Grease Zerk Boot Shield...

Page 184: ...5 24 BODY STEERING SUSPENSION X2 Torsion Bar Exploded View Linkage Bushing Stabilizer Bar Torsion Mount Linkage Asm Bushing Stabilizer Bushing...

Page 185: ...5 25 BODY STEERING SUSPENSION 5 X2 CARGO BOX Exploded View...

Page 186: ...e rear taillights on each side of the cargo box as illustrated below 2 Remove the taillight assembly from the cargo box 3 Disconnect the two wire harnesses connected to each of the taillights 4 Carefu...

Page 187: ...to the frame There are two on each side 8 Support the cargo box and remove the clip and pin holding the gas shock to the cargo box 9 Carefully remove the cargo box from the ATV 10 Reverse the removal...

Page 188: ...5 28 BODY STEERING SUSPENSION X2 SEAT ASSEMBLY Exploded Views...

Page 189: ...up on the passenger backrest loop that is face down in the cargo box 3 Lift the passenger backrest up and into place then lay the driver seat backrest down into place 4 Fold the driver seat backrest...

Page 190: ...ps Passenger Seat Backrest Removal Installation 1 Configure the seating for 2 UP riding Lift up on the latch for the passenger backrest and lift the backrest to the full up position 2 Lift up on the l...

Page 191: ...CLUTCH OFFSET 6 14 EBS DRIVE CLUTCH SERVICE 6 15 DRIVE CLUTCH DISASSEMBLY 6 15 SPIDER REMOVAL 6 15 BUTTON TO TOWER CLEARANCE INSPECTION 6 17 SHIFT WEIGHT INSPECTION 6 17 DRIVE CLUTCH INSPECTION 6 17...

Page 192: ...ler Pin Tool 2870910 Clutch Bushing Replacement Tool Kit 2871226 Piston Pin Puller 2870386 EBS Clutch Alignment Tool 2872292 EBS Bushing Replacement Kit 2201379 Clutch Compression Tool 8700220 Clutch...

Page 193: ...Components Drive Clutch Exploded Views Standard and Deluxe Clutch Inlet Duct Clamps Boot Duct Clutch Cover Clutch Cover Seal Seal Retainer Bracket Inner Seal Cover Inner Clutch Cover Transmission Cove...

Page 194: ...ew 2 Cam Assembly 3 Retaining Ring 4 E clip 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 Retaini...

Page 195: ...Clutch Drive Washer Spacer Shift Weights Roller Bushing Assembly Torque 200 ft lbs Spider Lock Nut Coil Spring Bushing Cover Drive Belt Cam Assembly Retaining Ring Spider Assembly Compression Spring...

Page 196: ...ive belt and the transmission input shaft If the torque resistance at the transmission input shaft is greater than the load from the drive belt the drive belt is kept at the outer diameter of the driv...

Page 197: ...to ensure maximum performance and service life of PVT components Refer to the troubleshooting checklist at the end of this chapter for more information 1 Drive to Driven Clutch Offset Belt Width See C...

Page 198: ...onents in insuring optimum performance It is very important that the spring is of correct design and is in good condition Measuring Spring Length With the spring resting on a flat surface measure its...

Page 199: ...shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough underst...

Page 200: ...ion to lowest available range and test for belt slippage Repeat as needed Operate ATV in lowest available range for a short period of time until PVT system is dry PVT Disassembly NOTE Some fasteners a...

Page 201: ...gine seal 2 Place a new seal on transmission input shaft 3 Apply RTV silicone sealant to outside edge of inner cover to engine seal to ensure a water tight fit between the seal and the cover on engine...

Page 202: ...Removal Inspection 1 Remove outer PVT cover as described in PVT Disassembly 2 Mark drive belt direction of rotation so that it can be installed in the same direction The belt is normally positioned so...

Page 203: ...not a specific center distance 10 Replace belt if worn past the service limit Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See Troubles...

Page 204: ...s Adjust if necessary NOTE On some models minor adjustments can be made by adding shims between the frame and front lower left engine mount to increase the distance at point A If a shim is present it...

Page 205: ...the bushing 4 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See Drive Clutch Spring Specification...

Page 206: ...st fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 4 Rubber backed but...

Page 207: ...ection see Roller Pin and Thrust Washer Inspection Drive Clutch Inspection NOTE Remove cover spring and spider following instructions for drive clutch removal then proceed as follows 1 Remove moveable...

Page 208: ...ct BOTH sheaves for signs of wear grooving or cracking De glaze surfaces with a 3M pad if needed Drive Clutch Bushing Service NOTE Special Tool Required EBS CLUTCH BUSHING REMOVAL AND INSTALLATION In...

Page 209: ...ear 9 Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller 10 Remove nut from puller rod and set aside 11 Pull bushing removal tool and adapter from puller rod Remove...

Page 210: ...5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod One Way Clutch Inspection Drive Clutch 1 Rotate...

Page 211: ...ge to the stationary sheave 6 Install limiter nut on top of spider using the Clutch Spider Nut Socket PN 2870338 Torque to specification Reinstall shift weights using new lock nuts on the bolts 7 Rein...

Page 212: ...s for reference This will aid in reassembly and helps to maintain clutch balance after reassembly 3 Remove the four torx screws that secure the cam assembly helix using a T25 torx 4 Place the clutch i...

Page 213: ...nspect the rollers for wear replace if worn 8 Remove the clutch assembly from the holding tool Remove the large outer retaining ring I and the inner retaining ring J 9 Press out the spring pins K in t...

Page 214: ...talling new bushing Driven Clutch Bushing Removal 1 Install main puller adapter Item 8 onto puller 2 Install adapter reducer Item 9 3 Using a hand held propane torch apply heat around outside of bushi...

Page 215: ...m 2 and install assembly into sheave 6 Install left hand thread nut C onto puller rod and hand tighten against installation tool 7 Turn clutch sheave counterclockwise making sure bushing is drawn stra...

Page 216: ...the marks previously used Put the sheaves together 5 Install the roller A onto the roller pin B Both Sides 6 Install the roller pin into the sheave assembly Both sides The flat side of the roller pin...

Page 217: ...Use the marks previously made to align the skip tooth spider or use the X on top of the spider and align it with the skip tooth on the shaft 13 Place the clutch into Clutch Compression Tool PN 870022...

Page 218: ...rker mark the cover spider and moveable and stationary sheaves for reference as the previous X s may not have been in alignment before disassembly 2 Remove cover bolts evenly in a cross pattern and re...

Page 219: ...Turn roller with your finger If you notice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing m...

Page 220: ...ooth and free of dents or gall marks Remove shift weight bolts and weights 2 Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of...

Page 221: ...d set aside 4 Install puller adapter Item 10 from kit PN 2871226 5 Install main adapter onto puller 6 With towers pointing toward the vise slide sheave onto puller rod 7 Install removal tool into cent...

Page 222: ...ver insert new bushing and bushing installation tool into center of clutch cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod an...

Page 223: ...he tower and cover Torque cover bolts evenly to specification T Spider Torque 200 ft lbs 271 Nm CAUTION Verify spider spacer washers are fully seated in the recessed area of the spider Any misalignmen...

Page 224: ...Separate the clutch sheaves by pulling upward while rotating the inner sheave Inspection 1 Inspect both the inner and outer sheave surfaces Replace the entire clutch assembly if worn damaged or cracke...

Page 225: ...all inner spring retainer if removed 2 Install the inner sheave onto the outer sheave NOTE Verify X marks on each side of the sheaves are aligned upon reassembly of sheaves 3 Install the compression s...

Page 226: ...ed to low ambient temperatures Warm engine at least 5 min then with transmission in neutral advance throttle to 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent...

Page 227: ...n clutch binding Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix Converter sheaves greasy belt slippage Clean sheaves with denatured alcohol or brake...

Page 228: ...Instruct firm effective use of throttle for efficient engagement PVT noise Belt worn or separated thin spots loose belt Replace belt Broken or worn clutch components cover hitting clutches Inspect and...

Page 229: ...ED VIEW STANDARD MODELS 7 11 OPERATION 7 12 GEARCASE REMOVAL 7 12 DISASSEMBLY INSPECTION 7 13 REASSEMBLY INSPECTION 7 17 SETTING RING GEAR BACKLASH 7 18 FRONT GEARCASE DIAGNOSIS 7 19 GEARCASE INSTALLA...

Page 230: ...Bolts 30 41 Standard Gearcase Screws 14 19 Lower Hub Carrier Bolts 50 68 Upper Hub Carrier Bolts 35 48 ADC Pump Screws 17 23 1 9 2 5 ADC Cover Screws 7 11 9 4 14 9 ADC Bleed Valves 80 9 PART NUMBER T...

Page 231: ...om lower A arm ball joint Remove lower A arm from ball joint 10 Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly 11 Pull strut assembly out while pivoti...

Page 232: ...tter pin 4 Install hub and tighten hub nut to specification FRONT DRIVE SHAFT CV BOOT Inspection Check the front and rear driveshaft CV boots for any tears or leaking grease If the driveshaft boot los...

Page 233: ...pe and quantity of grease Use only the grease contained in the boot kit DO NOT use a substitute grease and DO NOT overfill or under fill the CV joint 9 Slide the new clamp and boot small end first ove...

Page 234: ...arings 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...

Page 235: ...ear propshaft loosening and or removal of rear gearcase mounting bolts may be required to gain necessary clearance for propshaft removal U JOINT Disassembly 1 Remove internal or external snap ring fro...

Page 236: ...d center of shaft Take care not to dislodge needle bearings upon installation of cross joint Tighten vise to force bearing caps in 2 Using a suitable arbor fully seat bearing cap in one side Continual...

Page 237: ...t installed Repeat procedure for other side 6 Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 7 When installation is complete yokes must pivot fr...

Page 238: ...lip Inner CV Joint Circlip Inner Boot Outer Boot Circlip Outer CV Joint Drive Axle Components Drive Boot Replacement Kits Prop Shaft Components Clamps Outer Clamp Boot Clamp 3 5 oz grease Propshaft As...

Page 239: ...Plate Asm 1 14 Gearcase Sub Asm 1 4 O Ring 1 15 Ring Gear Clutch Housing 1 5 Retaining Ring 1 16 Output Hub Asm 2 6 Bearing 3 17 Roll Cage Asm 1 7 Pinion Gear Asm 1 18 Armature Plate 1 8 Pinion Bushin...

Page 240: ...ear and output hubs that link both front axles resulting in true all wheel drive Disengagement As the front and rear wheels gain equal traction rotating very close to the same speed the transmission s...

Page 241: ...uring the bottom of housing to the skid plate frame Bolts and fluid drain plug are accessible through the skid plate 9 Remove vent line 10 Remove the front gearcase from left side of frame pulling bot...

Page 242: ...utput hubs is pressed into assembly 4 Remove the armature plate and RH output hub assembly from the outer cover plate Inspect the bearing and contact surfaces of the output hub for signs of wear or da...

Page 243: ...st slide up and down freely within the roller cage surfaces 8 Inspect the ring gear C for consistent wear patterns The surfaces should be free of nicks or burrs 9 Inspect roll cage B sliding surface T...

Page 244: ...d screw is removed See the FRONT GEARCASE ASSEMBLY procedure later in this chapter for details on backlash setting 12 Remove the bolts retaining the input shaft cover and pinion gear assembly 13 Remov...

Page 245: ...y hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 4 Install input shaft...

Page 246: ...in gearcase NOTE Verify the square O ring arrow is placed flat on the cover surface If the O ring is twisted fluid leakage may occur 11 Torque the cover plate bolts to specification 12 Laythegearcaseo...

Page 247: ...t the gearcase coil resistance use the coil harness Grey Brown White NOTE To test the gearcase coil resistance use the coil harness The gearcase coil should measure between 22 8 ohms and 25 2 ohms 2 C...

Page 248: ...over Plate Assembly 5 Inspect the rollers for nicks scratches and flat spots Also inspect the roll cage for cracks and ensure the rollers are able to slide up and down and in and out freely within the...

Page 249: ...Clutch Assy LH Exploded View 1 21 Wire Connector 1 6 Vent 1 22 O ring Outer 2 7 Cap Bleed Screw 2 23 O ring Inner 2 8 Spacer Clutch Basket 1 24 Bleeder Valve 2 9 Cover Assembly 1 25 Cam Assembly 1 10...

Page 250: ...shaft coil 1 Operation is controlled by the ECU grounding and ungrounding the coil The coil s magnetic field attracts a splined armature plate 2 on the pinion input shaft 4 The energized splined armat...

Page 251: ...unter clockwise to loosen Loosen bleeder screw slowly allowing oil and any trapped air to flow out of fitting IMPORTANT Do not allow hydraulic fluid in reservoir to drain below minimum fill line Close...

Page 252: ...ates are steel on steel or if the friction material is worn the assembly should be replaced NOTE Excessive debris in the oil and or noise coming from the front drive on deceleration with ADC active ar...

Page 253: ...oller cage surfaces Inspect the ring gear 3 for consistent wear patterns Surfaces should be free of nicks or burrs 12 Inspect roll cage sliding surface 2 This surface must be clean and free of nicks b...

Page 254: ...replaced or the back lash pad screw is removed See the FRONT GEARCASE ASSEMBLY in this chapter for details on backlash setting 15 Remove the bolts retaining the input shaft cover and pinion gear assem...

Page 255: ...nt Procedure 1 Place ADC Piston Tool PA 48542 on top of the piston Using moderate hand pressure hold the tool on top of the piston while using compressed air at the gearcase passage circled to force p...

Page 256: ...nment 6 Place ADC Piston Tool PA 48542 on top of the piston and verify alignment of the sight hole circled and piston mark with the casting marks Support the case and press the piston down evenly The...

Page 257: ...l the pinion gear bearing assembly 1 Install a new seal and o ring the input shaft cover 2 prior to reassembly 4 Install the snap ring retaining the input shaft assembly 5 Install the eccentric cam as...

Page 258: ...s replaced or the back lash pad screw is removed 9 Install the roll cage and rollers into the ring gear Insert the rollers as the roll cage is installed 10 Install the clutch pack 1 spacer 2 and ring...

Page 259: ...mbly on Install bolts arrows retaining the outer cover plate assembly and torque to specification 15 Install a new passage o ring dotted circle on the gearcase and install the piston pump assembly Tor...

Page 260: ...Loosen the hub retaining nut B 4 Loosen the wheel nuts C 5 Safely support the rear of the ATV 6 Remove wheel nuts and wheel 7 Remove the rear brake caliper and safely suspend the caliper from the fram...

Page 261: ...bearing is at bottom of casting support casting on outer edges so bearing can be removed 3 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visua...

Page 262: ...ing into groove Installation 1 Insert bearing carrier on drive shaft 2 Align bottom of carrier housing and lower control arm Grease and slide lower control arm bushings into place securing corner hous...

Page 263: ...ue axle nut and wheel nuts to specification 9 Install a new cotter pin Tighten nut slightly to align holes if required REAR DRIVE CV SHAFT Removal 1 Remove rear hub see REAR HUB REMOVAL 2 Remove upper...

Page 264: ...ocate 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 while holding snap ring open 4 Place a new snap ring in the...

Page 265: ...fingers A gritty feeling indicates contamination If the grease is not contaminated the boot can be replaced without cleaning the CV joint Use the recommended amount of grease for boot replacement only...

Page 266: ...boot kit NOTE CV Joint Grease Capacity Outboard Joint 30g if boot is replaced only Another 50g 80 total if joint is cleaned Inboard Joint 50g if boot is replaced only Another 50g 100 total if joint i...

Page 267: ...potential damage to the driveshaft joints Over angling of joints beyond their capacity could result in boot or joint damage Make sure surface ground areas and splines of shaft are protected during ha...

Page 268: ...NOTES FINAL DRIVE 7 40...

Page 269: ...ECIFICATIONS 8 3 SPECIAL TOOLS 8 3 LUBRICATION 8 3 GEAR SELECTOR REMOVAL 8 3 TRANSMISSION REMOVAL 8 3 TRANSMISSION INSTALLATION 8 5 TROUBLESHOOTING CHECKLIST 8 6 TRANSMISSION SERVICE 8 7 EXPLODED VIEW...

Page 270: ...8 2 GENERAL INFORMATION TRANSMISSION GENERAL Mounting Exploded View x2 x3 x4 x4 x2 x1 x1 x1...

Page 271: ...lcrank C 7 Remove PVT outer cover drive and driven clutches and the inner PVT cover refer to Clutch Removal in Chapter 6 8 Remove both rear drive shafts Brake caliper removal is required Do not let ca...

Page 272: ...r 7 for more details 13 Remove all lower transmission mounting fasteners J from each side 14 Remove the middle transmission support bracket K completely from the ATV 15 Remove the rear transmission su...

Page 273: ...7Nm Torque all upper rear and middle support bracket bolts circled to 17 ft lbs 24 Nm 5 Install the upper control arms Refer to Chapter 5 for procedures and torque specifications 6 Reconnect the torsi...

Page 274: ...s to the transmission 15 Reconnect the shift rod Torque to standard specification 16 Install the rear wheel nuts and torque to specification 17 With the ATV on level ground add Polaris AGL Gearcase Lu...

Page 275: ...8 7 GENERAL INFORMATION 8 TRANSMISSION SERVICE Exploded View 262 242 THREAD LOCKING AGENT FOR ALL FT LBS FASTENERS THREAD LOCKING AGENT FOR INCH LBS FASTENERS...

Page 276: ...8 8 GENERAL INFORMATION 242 262 262 262 262 262...

Page 277: ...tor cover bolts 5 and remove the sector cover 6 Removal can be aided by using your thumbs to press down on the shafts and pulling up the cover with your fingers 6 Remove the compression spring 7 7 Rem...

Page 278: ...de the cam chain tensioner shoe 15 pins 16 and cam chain tensioner cam 17 from the assembly 13 Remove the differential gear 18 and chain by gently prying underneath or tapping the differential gear fr...

Page 279: ...Place the gear cluster assembly on a clean surface for inspection Gear Cluster Disassembly 18 Remove the bearing from the reverse shaft using a bearing puller Slide the engagement dog 1 off of the re...

Page 280: ...assemble the shift fork rail remove the snap ring 10 from the end of the shift rail on either side Transmission Snorkel Shaft Removal 27 Remove the snorkel lock screw located inside the gearcase Use a...

Page 281: ...snap ring 13 and spacer 14 from the snorkel shaft NOTE Shim may or may not be present Depending on input shaft tolerance 32 To remove the snorkel shaft from the snorkel tube use a press to press the s...

Page 282: ...for replacement 2 Reverse the disassembly procedure for the assembly of the snorkel shaft assembly 3 Inspect the output gear assembly 1 replace bearings if needed Inspect the 91T gear for nics chips...

Page 283: ...make sure the snorkel gear and output bevel gear are lightly seated or meshing so there is zero lash Do not overtighten Gears should rotate freely without binding Before turning the snorkel tube look...

Page 284: ...ly Remove the output shaft assembly 4 Assemble the input shaft assembly if previously disassembled 5 Assemble the reverse shaft assembly if previously disassembled Screw Fits in Slots of Snorkel Tube...

Page 285: ...be installed at the same time to properly align all components NOTE To ease assembly use a plastic tie strap to hold the shift forks D and the shift drum C together during assembly 9 With the gearcase...

Page 286: ...tial gear bearing may be lightly tapped into place The case half seal can be installed once the assembly is in place 13 Tensioner Installation NOTE Case halve mating may be difficult due to tensioner...

Page 287: ...nstall the shift gear 16T G on the shift drum shaft Install the sector gear F in the bushing pocket on the left side Aligning the timing marks on the gears 18 Install the O ring if not yet done and lo...

Page 288: ...Install the bellcrank onto the shift shaft Note the key splined on the bellcrank and shaft Install the nut Torque the nut to 12 18 ft lbs 16 26 Nm 23 Install the transmission switch and secure the swi...

Page 289: ...9 12 INSPECTION 9 12 REMOVAL REPLACEMENT 9 13 FRONT CALIPER 9 14 REMOVAL 9 14 INSPECTION 9 15 REASSEMBLY 9 15 INSTALLATION 9 16 REAR BRAKE PAD 9 17 X2 PAD REMOVAL 9 17 X2 PAD INSTALLATION 9 18 SPORTS...

Page 290: ...Sportsman Caliper Slide Pins 30 35 41 48 Rear Master Cylinder to Frame Bolts 8 11 FRONT BRAKE CALIPER Sportsman and X2 ITEM STANDARD SERVICE LIMIT Brake Pad Thickness 298 7 6 mm 180 4 6 mm Brake Disc...

Page 291: ...Fitting 15 ft lbs 21 Nm 3 Flare Style Fittings 12 15 ft lbs 16 21 Nm 4 Brake Switch 12 15 ft lbs 16 21 Nm Apply Pipe Sealant to Threads 2 2 1 2 2 3 3 2 2 3 4 All Bleed Screws 25 30 in lbs 2 80 3 40 Nm...

Page 292: ...n System Component Exploded View All Banjo Style Fittings 15 ft lbs 21 Nm All Flare Style Fittings 12 15 ft lbs 16 21 Nm All Bleed Screws 25 30 in lbs 2 80 3 40 Nm Apply Pipe Sealant To Threads 2 Scre...

Page 293: ...Asm D Boot E Square O rings F Piston G Caliper Mount H Brake PAds A B C D E F G H Apply Polaris All Purpose Grease 3 3 Apply Polaris DOT approved Brake Fluid to Component A Socket Set Screw B Bleeder...

Page 294: ...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...

Page 295: ...ecessary and discard the rest in accordance with local laws Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture This causes the boiling t...

Page 296: ...he brake lever until pressure builds and holds 7 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever NOTE Do not release lever before bleeder screw is tight...

Page 297: ...a clean work area to disassemble brake components 2 Remove master cylinder from handlebars 3 While holding upright continue to remove master cylinder Cover the brake line to avoid spillage when remov...

Page 298: ...er slowly two to three times with finger over the outlet end to purge master cylinder of air 4 Follow proper bleeding procedures Check all connections for leaks and repair if necessary FRONT BRAKES Pa...

Page 299: ...to caliper Remove excess fluid from reservoir as required 6 Push mounting bracket inward and slip outer brake pad past edge Remove inner pad 7 Measure the thickness of the pad material Replace pads if...

Page 300: ...reservoir and install reservoir cap 7 Install wheels and torque wheel nuts It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and redu...

Page 301: ...before applying heat to the bolts 1 Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent 2 Remove bolts and disc 3 Clean mating surface of disc and hub 4...

Page 302: ...lip brake pads past edge Loosen pad adjuster 3 Remove mounting bracket pin assembly and dust boot 4 Remove piston dust seals and piston seals 5 Clean the caliper body piston and retaining bracket with...

Page 303: ...ection See BRAKE PAD INSPECTION earlier in this chapter Reassembly 1 Install new caliper seals A in the caliper body B Be sure groove is clean and free of residue or brakes may drag upon assembly 2 Co...

Page 304: ...mounting bolts to specification 6 Install brake line and torque the banjo bolt to specification 7 Install the adjuster screw and turn until stationary pad contacts disc then back off 1 2 turn 8 Perfo...

Page 305: ...liper so as not to kink or bend brake line 5 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating...

Page 306: ...2 7 mm of brake fluid in the reservoir to prevent air from entering the brake system 5 Install the adjuster screw and turn clockwise until the stationary pad contacts the disc then back off 1 2 turn c...

Page 307: ...be careful not to damage brake line Support caliper so as not to kink or bend brake line 5 Push caliper pistons into caliper bore slowly with pads installed 6 Remove the caliper slide pins and remove...

Page 308: ...ommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Brake Burnishing Procedure Start machine and slowly increase speed to 30...

Page 309: ...nting bolts and the caliper 4 Loosen the adjuster screw and remove the brake pads 5 Remove mounting bracket pin assembly and dust boot 6 Remove piston dust seals and piston seals 7 Clean the caliper b...

Page 310: ...ection See BRAKE PAD INSPECTION earlier in this chapter Reassembly 1 Install new caliper seals A in the caliper body B Be sure groove is clean and free of residue or brakes may drag upon assembly 2 Co...

Page 311: ...s Place a container to catch brake fluid draining from brake lines 3 Remove the two caliper mounting bolts and the caliper 4 Remove the slide bolt snap rings A the slide pins B the bracket pad C and t...

Page 312: ...in bore Apply brake fluid to piston seals and install carefully with a twisting motion to ease assembly until fully seated 2 Carefully assemble caliper body making sure O rings are properly positioned...

Page 313: ...re check assembly and installation REAR BRAKE DISC Inspection 1 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident 2 Use a micrometer and measure...

Page 314: ...R MASTER CYLINDER X2 Exploded View A B D E F G I H C D E J A Master Cylinder Bolts B Rear Brake Line C Rear Master Cylinder D Bushing s E Washer s F Cotter Pin G FootPedal H Spring I Front Brake Line...

Page 315: ...re applicable Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely X2 Rear Master Cylinder Removal and Installation 1 Remove the RH footwell to ga...

Page 316: ...der mount the master cylinder to the mount plate and torque bolts to specification 5 Reinstall the brake line and torque the banjo bolt to specification depending on the style of fitting 6 Perform bra...

Page 317: ...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 or damaged master cylinder...

Page 318: ...NOTES BRAKES 9 30...

Page 319: ...RKING 10 23 TEST 8 SHIFT INDICATOR NOT WORKING 10 23 ACTIVE DESCENT CONTROL ADC COIL 10 24 OPERATION OVERVIEW 10 24 DIAGNOSING SYSTEM FAILURES 10 24 ALL WHEEL DRIVE AWD COIL 10 24 OPERATION OVERVIEW 1...

Page 320: ...R EXPLODED VIEW 10 48 STARTER DRIVE 10 49 PINION GEAR ANTI KICK OUT SHOE GARTER SPRING REPLACEMENT 10 49 STARTER SYSTEM TESTING FLOW CHART 10 50 BASIC WINCH WIRING 10 51 PRE WIRED MODELS 10 51 TROUBLE...

Page 321: ...Tools Ignition System Basic Electrical Components Table 10 1 PART NUMBER TOOL DESCRIPTION PV 43568 Fluke 77 Digital Multimeter 2870630 Timing Light 2870836 Battery Hydrometer 2460761 Hall Sensor Prob...

Page 322: ...7 Digital Multimeter PV 43568 This meter is used for when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc an...

Page 323: ...s and how they function Regulator The rectifier converts the output of the 3 phase alternator and applies it to the battery and the PDM loads The regulator monitors the battery voltage and shuts off t...

Page 324: ...tays activated until the KAP_EFI input goes high The ECM_RELAY output current is monitored by the micro controller If the over current threshold is exceeded for the pre programmed delay time the outpu...

Page 325: ...Battery Ground J1 P Unused J1 R Unused J1 S ECM_RELAY IPS to the power the ECM relay output CONNECTOR 2 PIN SIGNAL NAME DESCRIPTION IPS Intelligent Power Switch J2 A COIL 1 Input from stator coil win...

Page 326: ...use turn off after delay Time Delay 0 6 Sec Time above limit until SSCB trips Voltage 6 2 Vdc Min Battery voltage for BAT_PROT to remain on ECM RELAY OUTPUT Current Output 20 Amp Nominal continuous ou...

Page 327: ...ent 9 A Max pull in current when solenoid is energized Hold Current 2 A Max holding current when solenoid is energized TURF MODE Input 0 16 V Input voltage range TURF MODE Input Pull Down 5K Ohm Resis...

Page 328: ...tage The regulator shuts off current on the BAT pin if the batter exceeds the over voltage threshold A high voltage transient will cause the regulator to turn off for a short period of time If there t...

Page 329: ...ed on thermal recovery Once tripped this output will remain off until the key switch is cycled on and off again Lights Output The LIGHTS output uses a smart high side power switch The LIGHTS relay out...

Page 330: ...attery voltage for BAT_PROT to remain on ACC_PWR OUTPUT Output Current 10 25 Amp Max continuous current Nominal Current 26 Amp Current above which the output will shut off after 15 25 seconds Overload...

Page 331: ...uctuations from day to day are normal because of changes in humidity temperature and elevation Trip meter records the miles traveled by the ATV if reset before each trip or total miles to 999 To reset...

Page 332: ...fuel immediately Instrument Cluster Diagnostic Mode NOTE This gauge features auto shut off protection if the voltage on the DC bus is excessive This is usually the result of an open battery condition...

Page 333: ...nt is flowing through the AWD coil on models with switchable AWD Screen 4 Gear Circuit Diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge NOT...

Page 334: ...he wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number Turn Service Interval...

Page 335: ...e proper diagnostic tools to further diagnose the blink codes To recall blink codes fail codes from the ECM 1 Verify the ATV key switch is off and the transmission is in park 2 Turn the key switch ON...

Page 336: ...rea of the instrument cluster This will help the instrument cluster slide into the pod assembly more easily 2 Be sure the rubber grommet inside the pod is fully installed and that the indexing key is...

Page 337: ...10 19 ELECTRICAL 10 ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING TEST 1 No All Wheel Drive...

Page 338: ...10 20 ELECTRICAL TEST 2 No Speedometer Display TEST 3 No Reverse Speed Limit...

Page 339: ...10 21 ELECTRICAL 10 TEST 4 No AWD Hub Safety Limit...

Page 340: ...10 22 ELECTRICAL TEST 5 Reverse Speed Limiter Activated In Forward Gear TEST 6 Wheel Speed Sensor...

Page 341: ...10 23 ELECTRICAL 10 TEST 7 Fuel Gauge Display Not Working TEST 8 Shift Indicator Not Working...

Page 342: ...olt ohm meter IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 80 of all electrical issues are caused...

Page 343: ...n refer to FAN MOTOR CURRENT DRAW in this section Repair or replace as necessary If the fan runs with the sensor harness disconnected but will not turn on when the engine is hot check the coolant temp...

Page 344: ...perature Resistance table to determine if the sensor needs to be replaced NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to ON NOTE The fan may not functi...

Page 345: ...nnecting the black wire to ground which prevents ignition spark This is the same as turning the key or engine stop switch OFF NOTE Test the ETC switch at the harness connector ETC will not activate un...

Page 346: ...e electrical charge collapsing the coil field for ignition based on the ECM timing map CDI A 12 volt DC current is supplied directly from the battery to the CDI At the CDI a current is supplied to the...

Page 347: ...10 29 ELECTRICAL 10 Components of EFI Alternator and DC CDI Ignition System...

Page 348: ...10 30 ELECTRICAL EFI Ignition System Testing Flow Chart...

Page 349: ...l mount loose or corroded Incorrect wiring inspect color coding in connectors etc Faulty ignition coil winding measure resistance of primary and secondary Sheared flywheel key Flywheel loose or damage...

Page 350: ...into Park and start the engine With the engine running at idle observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the battery starts to charge amme...

Page 351: ...g RPM 1 Set the selector dial to measure AC Voltage 2 Start the engine and let it idle 3 While holding the ATV at a specified RPM separately measure the voltage across each leg of the stator by connec...

Page 352: ...Testing Diagrams Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condition connected and not kinked or pinched SPORTS...

Page 353: ...10 35 ELECTRICAL 10 PDM...

Page 354: ...olenoid using a suitable tool 2 Coat threads of new solenoid with anti seize compound or sealant 3 Thread new solenoid into gearcase housing Tighten to specification LIGHTING High Beam Headlight Bulb...

Page 355: ...p and harness assembly into the headlight assembly Turn the headlight harness clockwise to secure the head lamp into place Headlight Housing Relacement 1 Remove three Phillips screws on the headlight...

Page 356: ...h the headlight approximately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the h...

Page 357: ...ired 5 Remove the screw that secures the lower head lamp 6 Pull the head lamp out of the locking tab Low Beam Headlight Adjustment 1 The low beam can be adjusted slightly upward or downward 2 Loosen t...

Page 358: ...ower at the blue wire Brake Light Work Light Replacement The brake light A and the work light B are both located in the rear tail lamp housing 1 X2 Open the tailgate and remove the 2 torx head screws...

Page 359: ...st bulb housing to remove from lamp assembly and replace bulb Brake Light Switch Test 1 Remove the front cover 2 Disconnect wire harness from switch 3 Connect an ohmmeter across switch contacts Readin...

Page 360: ...he fuel sender harness wire B and wire C 4 With the sender float in the empty position the meter should read 5 ohms 5 Slowly tilt invert the tank so that gravity moves the sender float to the full pos...

Page 361: ...sories are located under the front cover The wires are 12 Volt wires and are Orange White in color To locate the wires remove the front cover The wires will be located in the main wire loom on the rig...

Page 362: ...ansmission signal and determines if the switch is in Neutral or Park When the conditions are met the PDM will activate SSCB 2 Pin N to ground the starter solenoid Pin G on SSCB 2 of the PDM senses whe...

Page 363: ...10 45 ELECTRICAL 10 Starter Lockout Diagram EFI Starter Lockout Diagram Sportsman 450...

Page 364: ...nspection Replacement 1 Measure resistance between starter input terminal and insulated brushes The reading should be 3 ohms or less Measure the resistance between the cable terminal and brush housing...

Page 365: ...stall the two small phenolic washers the large phenolic washer flat washer and nut Armature Testing 1 Remove armature from starter casing NOTE Note order of shims on drive end for reassembly 2 Inspect...

Page 366: ...condition and not twisted on the case 5 Align casing marks and install housing pushing back brushes while installing shaft in bushing 6 Reinstall starter motor housing bolts Make sure O Rings are in g...

Page 367: ...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 thrus...

Page 368: ...rter solenoid coil by connecting an ohmmeter between the solenoid wire and the solenoid mounting plate Check solenoid ground path by measuring resistance between mounting plate and battery negative te...

Page 369: ...10 51 ELECTRICAL 10 BASIC WINCH WIRING Pre wired Models...

Page 370: ...10 52 ELECTRICAL TROUBLESHOOTING DIAGRAMS Power On EFI Start Circuit EFI To ECU Pin 12...

Page 371: ...10 53 ELECTRICAL 10 Ignition Coil EFI Fuel Pump EFI...

Page 372: ...10 54 ELECTRICAL Fan EFI Charging System EFI...

Page 373: ...10 55 ELECTRICAL 10 All Wheel Drive EFI Transmission Switch EFI...

Page 374: ...10 56 ELECTRICAL Reverse Override EFI Differential Solenoid X2...

Page 375: ...vent plug from vent fitting Remove cell caps 2 Fill battery with electrolyte to upper level marks on case 3 Set battery aside to allow for acid absorption and stabilization for 30 minutes Removable C...

Page 376: ...level remove the battery and fill with distilled water only to the upper level line To remove the battery 1 Disconnect holder strap and remove covers 2 Disconnect battery negative black cable first fo...

Page 377: ...in the machine with the cables disconnected or store in a cool place NOTE Stored batteries lose their charge at the rate of 1 per day Recharge to full capacity every 30 to 60 days during a non use pe...

Page 378: ...d the cranking voltage drops below 9 5 volts during the test replace the battery Charging Procedure 1 Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging 2 C...

Page 379: ...Batteries Batteries must be fully charged before use or battery life will be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery s rated amp...

Page 380: ...nking the observed voltage should not drop below 9 5 volts 4 If the beginning voltage is 12 8 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery Low Mai...

Page 381: ...PLODED VIEW 11 4 500 EFI QUADRICYCLE EMISSIONS SYSTEM 11 5 OVERVIEW 11 5 500 QUADRICYCLE ELECTRICAL 11 6 TURN HAZARD SIGNAL DIAGRAM 11 6 NOTE This chapter illustrates components that are unique to the...

Page 382: ...brake is applied all brake calipers are active as braking pressure is routed from the foot brake master cylinder through the proportioning valve and distribution block exiting one line to the front ca...

Page 383: ...11 3 500 EFI INTERNATIONAL QUADRICYCLE 11 Exploded View Foot Brake Supply Hand Brake Supply...

Page 384: ...View The 500 EFI International Quadricycle Sportsman is equipped with a steering locking mechanism to prevent theft or unauthorized use Steering post removal may be required for lock service or repai...

Page 385: ...ir valve closes During idle through mid range RPM the air valve is open and air is drawn into the from the PVT intake duct The air valve assembly B opens and closes based on the vacuum pressure connec...

Page 386: ...11 6 500 EFI INTERNATIONAL QUADRICYCLE 500 INTERNATIONAL QUADRICYCLE ELECTRICAL Turn Hazard Signal Diagram...

Page 387: ...ystem Exploded View International 11 3 Brake System Exploded Views 9 3 Brake System Overview International 11 2 Brake Master Cylinder Removal 9 9 Brake Rear Auxiliary Brake 9 28 Brake Rear Auxiliary M...

Page 388: ...25 Engine Torque Specifications 3 3 Engine Valve Clearance Adjustment 2 25 ETC Operation Test 10 27 ETC Switch Operation 10 27 F Fan Control Circuit Operation 10 25 Fan Control Circuit Operation Testi...

Page 389: ...6 Piston Removal 3 28 Piston Ring Installation 3 30 3 43 Plastic Inserts 5 3 Power Distribution Module 10 5 Pre ride Checklist 2 10 Propshaft Removal 7 7 Publication Numbers 1 3 PVT Assembly 6 11 PVT...

Page 390: ...pecifications Engine Fastener Torque 3 3 Specifications Engine Service Data 3 4 Specifications Final Drive Torque Values 7 2 Specifications Front Gearcase Lubrication Type Capacity 7 2 Specifications...

Page 391: ...IX 5 IX Wheels Removal 2 32 Wheels Tire Pressure 2 32 Wheels Torque Table 2 32 Wire Diagram Winch Basic 10 51 Wire Diagrams Electrical 10 52 Work Light Switch 10 40 X X2 Seat Disassembly 5 30...

Page 392: ...IX 6...

Page 393: ...WD 1 WIRE DIAGRAM 2007 SPORTSMAN ACTIVE DESCENT CONTROL ADC WIRE DIAGRAM...

Page 394: ...WD 2 WIRE DIAGRAM INTENTIONAL BLANK PAGE...

Page 395: ...WD 3 WIRE DIAGRAM 2007 SPORTSMAN 450 WIRE DIAGRAM...

Page 396: ...WD 4 WIRE DIAGRAM...

Page 397: ...WD 5 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI STANDARD WIRE DIAGRAM...

Page 398: ...WD 6 WIRE DIAGRAM...

Page 399: ...WD 7 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI DELUXE WIRE DIAGRAM...

Page 400: ...WD 8 WIRE DIAGRAM...

Page 401: ...WD 9 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI INTERNATIONAL WIRE DIAGRAM...

Page 402: ...WD 10 WIRE DIAGRAM...

Page 403: ...WD 11 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 WIRE DIAGRAM...

Page 404: ...WD 12 WIRE DIAGRAM...

Page 405: ...WD 13 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 QUADRICYCLE WIRE DIAGRAM...

Page 406: ...WD 14 WIRE DIAGRAM...

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