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Polaris 2007 SPORTSMAN 700 X2 EFI, Service Manual

The Polaris 2007 SPORTSMAN 700 X2 EFI is a high-performing off-road vehicle, perfect for adventure seekers. To ensure smooth maintenance and repairs, a comprehensive Service Manual is available for free download on our website. Dive into the details and download the manual today at manualshive.com.

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UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

SAFETY ALERT WARNING  indicates a potential hazard that may result in severe injury or death to the operator, bystander or
person(s) inspecting or servicing the vehicle.

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE: 

NOTE provides key information by clarifying instructions. 

IMPORTANT: 

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac,  Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or
by contacting the nearest Polaris dealer.

WARNING

CAUTION

CAUTION

Summary of Contents for 2007 SPORTSMAN 700 X2 EFI

Page 1: ...ools 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 700 800 800 X2 EFI Service Manual PN 9920378 Copyright 2006 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due...

Page 2: ...TE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Loctite Registered Trademark of the Loctite Corporation Nyogel Trademark of Wm F Nye Co Fluke Registered Trademark of John Fluke Mfg Co Mity Vac Registered Trad...

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: ... 1 3 2007 SPORTSMAN 700 EFI 1 4 MODEL NUMBER A07MH68AX A07MH68AY A07MH68AZ 1 4 2007 SPORTSMAN 800 EFI 1 6 MODEL NUMBER A07MH76A A07MN76A A07MH76F 1 6 2007 SPORTSMAN X2 800 EFI 1 8 MODEL NUMBER A07TH76A A07TN76A 1 8 MISC NUMBERS CHARTS 1 10 PUBLICATIONS 1 10 PAINT CODES 1 10 REPLACEMENT KEYS 1 10 STANDARD TORQUE SPECIFICATIONS 1 11 SPECIAL TOOLS 1 11 SAE TAP DRILL SIZES 1 12 METRIC TAP DRILL SIZES ...

Page 6: ...ATION Engine and Machine Serial Numbers Be sure to refer to the engine model number and serial number 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 the cylinder coolant elbow The machine model number and serial number are important for vehicle identi...

Page 7: ...l No Owner s Manual PN Parts Manual PN 2007 Sportsman 700 EFI A07MH68A A07MN68A 9920374 9920375 2007 Sportsman 800 EFI A07MH76A A07MN76A 9920374 9920379 2007 Sportsman X2 800 EFI A07TH76A A07TN76A 9920632 9920903 2007 Sportsman 800 EFI International A07MH76F 9920374 9920379 Table 1 2 Paint Codes PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Sportsman 700 800 EFI Frame Black 9440 P 0...

Page 8: ... PVT w EBS 3 Non EBS 800 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 Change Rear Rack Extension 7 No Rack Extension Cast Aluminum Wheels 8 Steel Wheels Dual Exhaust 800 EFI only 9 Single Exhaust 800 EFI and X2 Wire Harness w Active Descent Control ADC 10 Standard Wire Harness E...

Page 9: ...Deluxe 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 Control ADC 3 No Active Descent Control ADC Cast Aluminum Wheels 4 Steel Wheels 1 2 3 4 Standard Model Pictured ...

Page 10: ...Category Dimension Capacity Length 83 in 205 74 cm Width 48 in 116 8 cm Height 48 in 119 4 cm Seat Height 34 in 86 4 cm Wheel Base 50 75 in 128 9 cm Dry Weight 770 lbs 326 6 kg Gross Vehicle Weight 1220 lbs 553 kg Front Rack Capacity 100 lbs 45 4 kg Rear Rack Capacity 200 lbs 90 7 kg Towing Capacity 1500 lbs 680 kg Body Style Spirit Hitch Tongue Capacity 150 lbs 68 kg ...

Page 11: ...amp Harness 20 amp ECU 15 amp Inst Cluster Voltage Regulator 6 amp Starting Electric Instrument Cluster Analog Speedo w LCD Table 1 6 2007 700 EFI Specifications Drivetrain Transmission Type Drumshift H L N Rev Park Transmission Capacity 15 oz 445 ml Front Gearcase Capacity CH 8 97 265 ml Rear Gearcase Capacity 5 oz 150 ml Gear Ratio Low Rev High Front Drive Rear Drive 7 49 1 5 11 1 2 70 1 3 82 1 ...

Page 12: ...ations Category Dimension Capacity Length 83 in 205 74 cm Width 48 in 116 8 cm Height 48 in 119 4 cm Seat Height 34 in 86 4 cm Wheel Base 50 75 in 128 9 cm Dry Weight 770 lbs 326 6 kg Gross Vehicle Weight 1220 lbs 553 kg Front Rack Capacity 100 lbs 45 4 kg Rear Rack Capacity 200 lbs 90 7 kg Towing Capacity 1500 lbs 680 kg Body Style Spirit Hitch Tongue Capacity 150 lbs 68 kg Deluxe Model Shown ...

Page 13: ...tarting Electric Instrument Cluster Analog Speedo w LCD Table 1 10 2007 800 EFI Specifications Drivetrain Transmission Type Drumshift H L N Rev Park Transmission Capacity 15 oz 450ml Front Gearcase Capacity CH 8 97 265 ml Front Gearcase Capacity ADC 9 3 275 ml Rear Gearcase Capacity 5 oz 150ml Gear Ratio Low Rev High Front Drive Rear Drive 7 49 1 5 11 1 2 70 1 3 82 1 3 10 1 Clutch Type PVT Std EBS...

Page 14: ...city Length 93 in 236 22 cm Width 48 in 116 8 cm Height 48 in 119 4 cm Seat Height 34 in 86 4 cm Wheel Base 57 in 128 9 cm Dry Weight Standard 839 lbs 380 5 kg Deluxe 874 lbs 396 kg Gross Vehicle Weight 1500 lbs 680 3 kg Front Rack Box Capacity 90 lbs 40 8 kg Rear Box Capacity 400 lbs 181 4 kg Towing Capacity 1500 lbs 680 kg Body Style Spirit Hitch Tongue Capacity 150 lbs 68 kg Standard Model Show...

Page 15: ... Hr Fuses Fan 20 amp Harness 20 amp ECU 15 amp Inst Cluster Voltage Regulator 6 amp Starting Electric Instrument Cluster Analog Speedo w LCD Table 1 14 2007 800 X2 EFI Specifications Drivetrain Transmission Type Drumshift H L N Rev Park Transmission Capacity 32 oz 946 3ml Front Gearcase Capacity CH 8 97 265 ml Front Gearcase Capacity ADC 9 3 275 ml Gear Ratio Low Rev High Front Drive 23 91 1 21 74...

Page 16: ...4 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 Metric Torque 6 x 1 0 72 78 In lbs 8 x 1 25 14 18 ft lbs 10 x 1 25 26 30 ft lbs SPECIAL TOOLS Special tools may be required while servicing this vehicle Some of the tools listed or ...

Page 17: ...4 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 6...

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 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 19: ... to make contact with the drive belt ft Foot feet Foot Pound Ft lb A force of one 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...

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

Page 21: ...2 16 SPARK PLUG 2 16 ACTIVE DESCENT CONTROL ADC RESERVIOR LEVEL 2 16 BATTERY MAINTENANCE 2 17 COOLING SYSTEM 2 17 COOLANT STRENGTH TYPE 2 18 COOLING HOSES 2 18 RADIATOR 2 18 COOLING SYSTEM PRESSURE TEST 2 18 RESERVOIR LEVEL INSPECTION 2 18 RADIATOR COOLANT LEVEL 2 19 AIR FILTER SERVICE 2 19 AIR BOX SEDIMENT TUBE 2 20 ENGINE BREATHER 2 20 PVT INSPECTION DRYING PROCEDURE 2 21 ENGINE GROUND 2 21 ENGI...

Page 22: ...OVAL FRONT OR REAR 2 28 WHEEL INSTALLATION 2 28 TIRE PRESSURE 2 29 TIRE INSPECTION 2 29 FRAME NUTS BOLTS FASTENERS 2 29 FRONT REAR STORAGE COMPARTMENTS 2 29 WARN WINCH OPERATION IF EQUIPPED 2 30 CLEANING AND STORAGE OF ATV 2 32 ...

Page 23: ...vel begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause 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 to severe use decrease inte...

Page 24: ...t clean often E AirBoxSediment Tube Daily Drain deposits when visible Coolant if applicable Daily Check level daily change coolant every 2 years Head lamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed Recoil housing if applicable Weekly Drain water as needed check often if operating in wet conditions E Brake Pad Wear...

Page 25: ...0 Lubricate Rear Suspension 50 H 6 M 310 500 Lubricate E Throttle Cable ETC Switch 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary E Air intake ducts 50 H 6 M 310 500 Inspect ducts for proper sealing air leaks Drive belt 50 H 6 M 310 500 Inspect adjust replace as needed Cooling system if applicable 50 H 6 M 310 500 Inspect coolant strength seasonally pressure test system yearly E En...

Page 26: ...uting security apply dielectric grease to connectors subjected to water mud etc Clutches drive driven 100 H 12 M 620 1000 Inspect clean replace worn parts Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed Brake fluid 200 H 24 M 1240 1000 Change every two years ADC fluid 200 H 24 M 1240 1000 Change every two years Spark arrestor 300 H 36 M 1860 3000 Clean out E Idle Speed Adjust a...

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

Page 28: ...ontrol 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 Prop Shaft Between Transmission and Front Gearcase Transmission Muffler Right Side View Auxiliary Brake Port under access panel Drive Unit Battery Under Tank Rear Drive CV Shafts ...

Page 29: ...emium 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 U JointLube 14 oz 10 count 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogel Coolant 2871323 60 40 Coolant Gallon 6 count 2871534 60 40 Coolant Quart 12 count Additives Sealants Thread Locking...

Page 30: ...on 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 secured by cotter pins 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 damaged or loose nuts bolts or f...

Page 31: ... 25 50 hours 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 3A 3B Front Gearcase ADC Fluid Demand Drive LT Premium Hub Fluid Polaris ADC Hydraulic Drain as directed Add specified quantity Gearcase Change annually ADC Change fluid every 2 years 4 Rear Gearcase ATV Angle Drive Fluid Dr...

Page 32: ...arcase Lubricant 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 reinstall drain plug A using a new sealing washer B Torque to specification 3 Remove fill plug Inspect the O ring 4 Fill with the recommended fluid amount or to the bottom of the fill plug hole thread...

Page 33: ...e drain and fill plug use a 5 16 hex for removal and installation To Change Lubricant 1 Remove transmission drain plug to drain the oil Discard used oil properly 2 Clean and reinstall the drain plug Torque to specification 3 Remove fill plug 4 Add the correct amount of Polaris AGL Gearcase Lubricant 5 Check for leaks 6 Install fill plug Torque to specification SPORTSMAN Oil Fill Plug Oil Fill Leve...

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 before oil level falls below minimum fill line Refilling empty reservoir will result in air pockets becoming trapped NOTE If empty reservoir is encountered filling of fluid is still possible Verify ai...

Page 35: ...ile lifting on the cover to release 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 Slide boot off throttle cable adjuster and jam nut 2 Place shift selector in neutral and set parking brake 3 Loosen lock nut on in line cable adjuster Ill 1 4 Turn ...

Page 36: ...n is abnormally high A cylinder leakdown test is the best indication of engine condition Follow manufacturer s instructions to perform a cylinder leakage test Never use high pressure leakage testers as crankshaft seals may dislodge and leak WARNING Gasoline is extremely flammable and explosive under certain conditions EFI components are under high pressure Verify system pressure has been relieved ...

Page 37: ... Adjust gap if necessary by bending the side electrode carefully 6 If necessary replace spark plug with proper type 7 Apply a small amount of anti seize compound to the spark plug threads 8 Install spark plug and torque to specification Active Descent Control ADC Reservoir Level The Active Descent Control reservoir DELUXE Models Only is located by the radiator fill cap Check the level and verify i...

Page 38: ...ery attaching positive red cable first and then the negative black cable 10 Reattach vent hose making sure it is properly routed and not kinked or pinched 11 Coat terminals and bolt threads with Dielectric Grease PN 2871329 12 Reinstall battery cover and holder strap Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the re...

Page 39: ... low pressure water Cooling System Pressure Test See Chapter 3 for pressure test procedures Reservoir Level Inspection Remove any obstructions with compressed air or low pressure water With the engine at operating temperature the coolant level should be between the upper and lower marks on the coolant reservoir If it is not 1 Remove reservoir cap Verify the inner splash cap vent hole is clear and ...

Page 40: ...r of the seat 2 Pull the seat back and free of the tabs NOTE When reinstalling seat make sure the slots in the seat engage the tabs in the fuel tank 3 Remove clips A from air box cover and remove cover Inspect the gasket It should adhere tightly to the cover and seal all the way around 4 Loosen clamp and remove air filter assembly Cleaning 5 Slip the pre filter element off of main element Clean th...

Page 41: ...ain tube 3 Reinstall drain plug NOTE The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods Engine Breather Four cycle ATV engines are equipped with a engine breather filter The in line filter is similar in appearance to a fuel filter The breather lines are located on top of the cylinder head cover below t...

Page 42: ... the belt and clutches Allow engine RPM to settle to idle speed shift transmission to lowest available range and test for belt slippage Operate ATV in lowest available range for a short period of time until PVT system is dry Engine Ground Inspect engine to frame ground cable connection Be sure the connection clean and tight Engine Oil Level The twin engine is a wet sump engine meaning the oil is c...

Page 43: ... Run engine two to three minutes until warm Stop engine 3 Clean area around drain plug at bottom of engine 4 Place a drain pan beneath crankcase and remove drain plug 5 Allow oil to drain completely 6 Replace the sealing washer on drain plug NOTE The sealing surfaces on drain plug and oil tank should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to specification 8...

Page 44: ...teering tie rod pull in all directions feeling for movement Repeat inspection for inner tie rod end on steering post Replace any worn steering components Steering should move freely through entire range of travel without binding Elevate front end of machine so front wheels are off the ground Check for any looseness in front hub wheel assembly by grasping the tire firmly at top and bottom first and...

Page 45: ...o 6 cm wider than the measurement at the rear B Toe Alignment If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure handlebars are straight ahead before determining which tie rod s need adjustment To Adjust Toe Alignment Hold tie rod end to keep it from rotating Loosen jam nuts at both end of the tie r...

Page 46: ...gs Brake System Inspection The following checks are recommended to keep the brake system in good operating condition Service life of brake system components depends on operating conditions Inspect brakes in accordance with the maintenance schedule and before each ride Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir See Chapter 9 Use Polaris DOT approved Br...

Page 47: ... Inspection Check brake system hoses and fittings for cracks deterioration abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts Auxiliary Rear Brake Test The auxiliary brake A should be checked for proper function 1 Support the rear wheels off the ground In mm Brake Pad Service Limit 180 4 6 mm Sight Glass Parking Lock Brake Measure Thickness Brake Pad A ...

Page 48: ... procedure outlined in Brake Chapter 9 Suspension Spring Preload Adjustment Operator weight and vehicle loading affect suspension spring preload requirements Adjust as necessary Use Shock Spanner Wrench PN 2870872 to adjust the rear springs Front Suspension Compress and release front suspension Dampening should be smooth throughout the range of travel Check all front suspension components for wear...

Page 49: ...tion 1 With the transmission in park 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 the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts to the proper torque listed in the table Item Specific...

Page 50: ...torage Compartments The front and rear storage Sportsman Only compartments are easily accessible To open the front compartment turn the latch handle to the horizontal position on both sides To close the storage compartment turn the latch handles to the vertical position CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle Table 2 1 TIRE PRESSURE INS...

Page 51: ...into the winch and OUT feeds the cable out of the winch Winch Control The winch control located on the side of the winch gives the operator easy access to switch between ENGAGED and FREESPOOL When the winch is ENGAGED the winch only allows the cable to be pulled IN or released OUT via the mini rocker switch on the handlebar When the winch is FREESPOOL the winch allows the cable to be pulled out fr...

Page 52: ...on instructions for more details Locate the Red wire 6 Ga with the yellow 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 control power to the winch Winch Connector Splash Guard for Contactor mount Winch Connecting Harness Right Side Front Fender Winch ...

Page 53: ...e container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and the fuel system Oil and Filter Warm the engine and change the oil and filter Follow the procedure in this chapter for proper oil change Air Filter Air Box Inspect and clean or rep...

Page 54: ...reeze 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 tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent cond...

Page 55: ...isters with a soft brush and soapy water 2 Use a cleaner such as HPC HiPerWash to clean away any remaining grime salts or oils 3 If the canisters are stained from oils or other fluids use fine steel wool with HPC Liquid Buff Cleaner and Polish to remove the stain 4 After removing the stains polish using Liquid Buff and a soft cloth Repeat this procedure as often as desired to maintain the finish C...

Page 56: ...2 36 MAINTENANCE Maintenance Schedule Service Date Hours Miles Service Performed Serviced By ...

Page 57: ...EMBLY EXPLODED VIEW 3 20 ROCKER ARMS 3 21 PUSH RODS 3 21 CYLINDER HEAD REMOVAL 3 21 CYLINDER HEAD INSPECTION 3 22 CYLINDER HEAD WARP 3 22 VALVE SEAL SPRING SERVICE ON ENGINE 3 22 CYLINDER HEAD DISASSEMBLY 3 23 VALVE INSPECTION 3 24 COMBUSTION CHAMBER 3 25 VALVE SEAT RECONDITIONING 3 25 CYLINDER HEAD REASSEMBLY 3 27 VALVE SEALING TEST 3 28 CYLINDER REMOVAL 3 28 VALVE LIFTER REMOVAL INSPECTION 3 28 ...

Page 58: ...in lbs 6 8 68 Nm 192 24 in lbs 21 7 2 7 Nm 115 12 in l 13 1 35 Nm 60 6 in l 6 8 68 Nm NOTE If needed heat the oil baffle bolts with a heat gun to remove 22 2 ft lbs 30 3 Nm A JournalBearings B Camshaft C ThrustPlate D Balance Shaft E Woodruff Key F Flange Seal G Crankshaft H Oil Pickup I Journal Bearings J Baffle K Oil Plug L Washer M O ring N Crankcase O Crankcase Bolts ...

Page 59: ...lts N Gear Stator cover O Wire Hold down P StatorHousingBolts A B C D E F G H I J K L M N O P 22 2 ft lbs 30 3 Nm 84 8 in lbs 9 5 90 Nm Apply corrosion resistant grease to stator grommet area 96 3 in lbs 10 85 0 35 Nm 108 12 in lbs 6 8 68 Nm Oil Pump Bolt Tighten Sequence Apply White Lithium Grease Apply Polaris OW 40 oil to component Mag Cover Bolt Tighten Sequence No Grease on this Portion of th...

Page 60: ...Washer N Flywheel O Bendix Apply Polaris Starter Grease Apply Polaris 0W 40 oil to seal Loctite Pipe Sealant PN 2871956 A 1 2 Tighten Top Bolt First 84 8 ft lbs 9 5 0 9 Nm No Grease or Oil B C D E F G H I J K L M N O 108 12 ft lbs 12 1 35 Nm 96 12 in lbs 10 85 1 35 Nm 65 7 ft lbs 88 9 5 Nm 96 12 in lbs 10 85 1 35 Nm Water Pump Cover Bolt Tighten Sequence Stator Cover Bolt Tighten Sequence ...

Page 61: ...B Oil Fill Tube C Dipstick D O ring E Hex Plug F Oil Filter Nipple G Oil Filter H Dowel I GalleyPlug J Nut washer K Spring A B C D E F G H I J 50 5 in lbs 5 65 0 56 Nm 35 4 ft lbs 47 5 5 4 Nm 18 2 ft lbs 24 4 2 71 Nm 22 2 ft lbs 30 3 Nm 50 5 in lbs 5 64 0 56 Nm K ...

Page 62: ...pply 0W 40 to lifters A Head Bolts B Rocker Arms C HeadAssembly D Gasket E Pushrods F Bushing G Expansion Plug H Cylinder I PistonAssembly J Circlip K Gasket L Hydraulic Lifter A B C D E F G H I J K L Apply each Bolt Threads 1 2 3 4 4 5 6 3 Circlip UP for Install Do Not install expansion plug more than 1 5 mm inward Apply Polaris 0W 40 Oil Apply Moly Lube Grease Side View Initial 35 4ft lbs 47 5 5...

Page 63: ...t lbs 24 5 2 7 Nm A Screws B Rocker Cover C Breather D O ring Seal E Breather Bolts F Spark Plugs G Carburetor Boot H Bolts I Boot Clamp J Throttle Body K Crank Position Sensor L Thermistor M O ring N Thermostat Housing O Bolts P Gasket Q Exhaust Manifold R Bolts S Thermostat A B E C D F Apply Dielectric Grease to threads of Spark Plug G H I J Apply Corrosion Resistant Grease K L M N O P Q 18 2 ft...

Page 64: ...3 8 ENGINE EFI Harness Exploded View A Fuel Injector B Fuel Rail C EFI Harness A B C 18 2 ft lbs 24 5 2 7 Nm NOTE See Chapter 4 for more information on the EFI system ...

Page 65: ...0 3 Nm Crankcase Bolt Tighten Sequence Lubricate threads and between washer and underside of bolt with engine oil Torque in sequence to spec provided allow the gasket to set for 1 minute then tighten in sequence 90 1 4 turn 35 4 ft lbs 47 5 5 5 Nm 90 1 4 turn ...

Page 66: ...agneto Cover 6 mm 96 3 10 85 0 35 Oil Baffle Weldment 5 mm 60 6 6 8 0 68 Oil Drain Bolt Crankcase 12 mm 192 24 21 7 2 7 16 21 7 Oil Fill Tube Bolt 5 mm 50 5 5 64 0 56 Oil Filter Pipe Fitting 20 mm 35 4 47 5 5 4 Oil Pick Up 5 mm 60 6 6 8 0 68 Oil Pressure Relief Plug 10 mm 22 2 30 3 Oil Pump Housing Screw 6 mm 84 8 9 50 0 90 Rocker Arm 8 mm 22 2 30 3 Rocker Cover 6 mm 84 8 9 5 0 9 Spark Plug 14 mm ...

Page 67: ... 3 478 88 35 mm Valve Seat Valve Seat Contacting Width Intake 0 0472 0 00787 0 0039 1 20 0 20 0 10mm Valve Seat Contacting Width Exhaust 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Valve Seat Angle 45 5 0 255 Valve Guide Valve Guide Inner diameter 0 2367 0 00029 6 012 0 007 mm Valve Guide Protrusion Above Head 0 807 0 0039 20 50 0 01 mm Valve Valve Margin Thickness Intake Standard 0 79 20 06 mm Max 0 ...

Page 68: ...ard 0 84245 0 00025 21 39 8 0 00635 mm 0 84245 0 00025 21 39 8 0 00635 mm Lifter Block Bore 0 8438 0 00062 21 4322 0 0157 mm 0 8438 0 00062 21 4322 0 0157 mm Piston Piston Standard 3 1477 000121 79 954 003mm 3 14803 00028 79 960 007 mm Piston Standard Inner Diameter of Piston Pin Bore 0 78789 00009 20 0125 0 003 mm 0 70902 00012 18 009 0 003 mm Piston Pin Piston Pin Outer Diameter 0 7874 0 7872 20...

Page 69: ...nnecting Rod Small End I D 0 789 0 78841 20 030 20 015 mm 0 7096 0 70846 18 17 995 mm Connecting Rod Small End Radial Clearance 0 0098 0 00039 0 025 0 010mm Same Connecting Rod Big End Side Clearance 0 01181 0 00591 0 030 0 015mm Same Connecting Rod Big End Radial Clearance 0 0015 0 00006 0 0038 0 0015mm Same Crankshaft Crankshaft Runout Limit 0 00236 0 060mm Same PART NUMBER TOOL DESCRIPTION PV 4...

Page 70: ...g System Specifications Recommended Coolant Use only high quality antifreeze coolant mixed with distilled water in a 50 50 or 60 40 ratio depending on freeze protection required in your area CAUTION Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation resulting in possible engine damage Polaris Premium 60 40 Antifreeze...

Page 71: ... neck or there is a dropping of the coolant level indicating that coolant has been pulled into the system NOTE Slowly squeezing the hose after the bend below the filler neck will aid in purging the system of air Pump the hose using your hand several times as shown in the diagram Elevating the rear of the ATV with a floor jack rear tires 4 6 off the ground also aids the purging of air from the syst...

Page 72: ...Remove throttle body A Insert a shop towel into the engine intake to prevent dirt from entering the ports 9 Relieve the fuel pressure in the fuel rail refer to Chapter 4 FUEL INJECTION for proper procedure Carefully remove the fuel rail B and injectors 10 Disconnect spark plug high tension leads 11 Remove the crank position sensor E located on the mag cover 12 Remove the air breather line 13 Disco...

Page 73: ...ctor and secure out of the way 17 Disconnect coolant temperature sensor wire located on the cylinder 18 Remove engine to chassis ground cable 19 Remove all engine mount nuts and or engine mount plates Remove the frame brace G from the front left side of the frame 20 Remove the engine from the left side of the frame NOTE Use caution when lifting the engine out of frame Use an engine lift or other m...

Page 74: ...iod The break in period for a Polaris ATV engine is defined as the first ten hours of operation or the time it takes to use two full tanks of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully 1 Fill fuel tank with unl...

Page 75: ...cylinder to heat up during honing After honing has been completed inspect cylinder for thinning or peeling If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable Hone only enough to de glaze the outer layer of the cylinder bore IMPORTANT Clean the cylinder after honing If cylinder wear or damage is ...

Page 76: ...res and then drains back to the crankcase sump The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump The oil pressure switch is fed off the main oil galley Engine Lubrication Specifications OIL PRESSURE TEST 1 Remove blind plug sender from left side of crankcase 2 Insert a 1 8 NPT oil pressure ...

Page 77: ...21 ENGINE 3 ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Rocker Arms Spring Retainers Retainer Locks keepers Springs Valve Seals Cylinder Head Valves Hydraulic Lifters Push Rods ...

Page 78: ...oves roughness or excessive wear 4 The push rods A can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness 5 If the push rod A is visibly bent it should be replaced Cylinder Head Removal 1 Loosen the six cylinder head bolts eve...

Page 79: ... valve cover rocker arms and pushrods align the cylinder to be worked on at top dead center TDC Install the Valve Pressure Hose PU 45652 into the spark plug hole Hook the hose to an air compressor and supply 50 to 100 psi to the hose This will seat the valves during valve spring removal Do not remove air from the hose at anytime until reassembly is completed 2 Using the Valve Spring Compressor PU ...

Page 80: ...t of specification 3 Remove valve guide seals IMPORTANT It is recommended to replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildup 4 Mark the valves with a white pen Remove the valves from the cylinder head This will ensure that the valves are properly placed during engine reassembly In mm Valve Spring ...

Page 81: ...tem with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications 6 Measure valve guide C inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer Measure in two directions 7 Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance NOTE The valve guides ca...

Page 82: ...the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit PN 2200634 Abrasive stone seat reconditioning equipment can also be used Keep all valves in order with their respective seat NOTE Valve 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 circumference o...

Page 83: ... check where the Prussian Blue indicates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be the proper width If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too high on the valve face Use the 30 cutter to lower the valve seat If too low use the 60 cutter to raise the seat Wh...

Page 84: ...at process for the other valve s 12 Thoroughly clean cylinder head and valves Cylinder Head Reassembly NOTE Assemble the valves one at a time to maintain proper order 1 Apply engine oil to valve guides and seats 2 Coat valve stem with molybdenum disulfide grease or 0W 40 Synthetic oil 3 Install valve carefully with a rotating motion to avoid damaging valve seal 4 Valve seals should be installed af...

Page 85: ...orward and backward while lifting it from the crankcase supporting pistons and connecting rods Support pistons with Piston Support Block PN 2870390 Valve Lifter Removal Inspection 1 Remove the valve lifter s by reaching into the crankcase and pushing the lifter up through the lifter bore by hand 2 Thoroughly clean the lifters in cleaning solvent and wipe them with a clean lint free cloth 3 Mark th...

Page 86: ...emove top compression ring Using a piston ring pliers Carefully expand ring and lift it off the piston CAUTION Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as shown spread the ring open and push up on the opposite side Do not scratch the ring lands 4 Repeat procedure for second ring 5 Remove the oil control rin...

Page 87: ... dial bore gauge Measure in two different directions front to back and side to side on three different levels 1 2 down from top in the middle and 1 2 up from bottom Record measurements If cylinder is tapered or out of round beyond 002 the cylinder must be replaced In mm Cylinder Warp 004 0 1 mm Max Measure at different points on surface A B A B C In mm Cylinder Taper Limit 002 9 05mm Max Cylinder ...

Page 88: ...ce piston and or piston pin if out of tolerance 3 Measure connecting rod small end ID Piston to Cylinder Clearance See 700 800 EFI Engine Service Specifications on page 3 11 Piston O D See 700 800 EFI Engine Service Specifications on page 3 11 Piston Pin Bore See 700 800 EFI Engine Service Specifications on page 3 11 5 mm Piston Piston Pin Piston Pin O D See 700 800 EFI Engine Service Specificatio...

Page 89: ... ends until gap is within specified range NOTE Always check piston ring installed gap after re 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 oil immediately to remove residue and prevent rust Starter Drive Bendix Removal Inspection 1 Remove stator housing bolts and rem...

Page 90: ... washer 3 Install Flywheel Puller PN 2871043 and remove flywheel A CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 4 Use caution when removing the wire holddown B trigger coil C and the stator assembly D Do not tap or bump the gear stator housing cover or the stator This could cause the seal around the gear stator housing cover and the crankcas...

Page 91: ... Puller PN 2871043 and remove flywheel F CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 5 Remove the starter bendix G wire holddown plate H and the woodruff key I from the crankshaft The stator does not have to be removed at this point 6 Remove the gear stator housing bolts and remove the gear stator housing cover J and gasket from the crankca...

Page 92: ... timing mark as shown 10 Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears If there is no tension check the springs inside of the cam gear assembly 11 The cam gear assembly contains three loaded springs To open the cam gear assembly Place the cam gear on a flat surface with the timing mark side facing up While holding both gears to...

Page 93: ...lowly push the dowel through the hole until the end of the dowel is almost flush with the spring Perform this procedure with all three tapered pins Do not push the pins too far through or the springs will pop out NOTE Do not remove the tapered pins at this time 17 Note in the photograph that the Tapered Pins PU 45497 1 are below flush with end of the springs This helps to align the three gear tabs...

Page 94: ...n the teeth of the cam gears as shown in the picture NOTE Install the Cam Gear Alignment Tool PU 45497 2 into one assembly hole counter clockwise from the timing mark NOTE For ease of installing the Cam Gear Alignment Tool PU 45497 2 R use a twisting motion when pushing down on the tool 21 To remove the balance shaft gear the flat side of the camshaft P must face the balance shaft gear To rotate t...

Page 95: ...24 Install the two puller bolts R Tighten the puller bolts up so that the bolts are at equal length 25 Install the Flywheel Puller PN 2871043 and remove the crankshaft gear if needed 26 Rotate the water oil pump gear S so that all four bolts are visible though the gear Remove the four bolts with a hex wrench Pull out the pump 27 Inspect the oil pump rotors for wear Mark the rotors with a white pen...

Page 96: ...her and bolt Torque to specification NOTE Be sure to place the tapered end of the valve dowel in first If the valve is installed incorrectly oil pressure and oil priming problems will occur 31 Carefully press the gear off the assembly while supporting the housing assembly 32 Remove the snap ring from the assembly Place the housing in a support and press out the bearing shaft assembly T 22 2 ft lbs...

Page 97: ...mbly into the housing as bearing damage may result Install retaining ring 36 Press gear onto shaft while supporting the housing 37 Remove thrust plate U 38 Remove PTO end engine mount Remove crankcase bolts Tap on the reinforced areas on the cases using soft hammer Carefully separate the two crankcase halves Bearing New Bearing Press Bearing Shaft Assembly using outer race only U Separate Crankcas...

Page 98: ...crankshaft 41 Remove and inspect crankshaft main journal bearings for abnormal wear It is recommended to replace the bearings anytime the engine is disassembled NOTE Plain bearing clearances may be checked using a commercially available plasti gauge material Camshaft Inspection 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage 3 Measure height of each cam...

Page 99: ...t B Torque bolts to specification 3 Install the balance shaft Inspect balance shaft clearance C in both gearcase halves Rotate balance shaft to ensure that there is clearance between it and oil baffle weldment In mm Camshaft Journal O D A Mag 1 654 00039 42 010 mm B Ctr 1 634 00039 41 50 010 mm C PTO 1 614 00039 41 010 mm In mm Camshaft Journal Bore I D Mag 1 656 0 00039 42 07 0 010mm Ctr 1 637 0 ...

Page 100: ... journals and bearings 6 Apply Crankcase Sealant PN 2871557 to the top gearcase halve NOTE Do not apply sealant to cam relief hole E 7 Assemble the crankcase halves Apply LocTite 242 PN 2871949 to the threads and pipe sealant to the bolt flanges Torque bolts to specification following torque pattern at beginning of this chapter 8 Lubricate cam lobes and valve lifters with Moly Lube Grease C D T Cr...

Page 101: ...et alignment 12 Orientate the piston rings on the piston before installation into the cylinders Set the gaps of the rings evenly 120 apart see illustration 13 Install piston assemblies into cylinder aligning the piston pin holes to ensure proper alignment of the pistons to the connecting rods upon assembly Partially install the piston pins into the pistons NOTE To help align the pistons slide a ro...

Page 102: ...clip could fall into the engine during installation 16 Install camshaft thrust plate G with new bolts Torque bolts to specification NOTE New bolts have patch lock on the threads and do not require Loctite 17 Assemble rotors as marked when disassembled Use a cleaner to remove the marks previously made on the rotors 18 Apply assembly lube or oil to the rotors on the oil pump shaft Push In Piston Pin...

Page 103: ...s outward or away from the case NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts and new Loctite 20 Install oil pump housing bolts H The new bolts contain patch lock so Loctite is not needed on the new bolts Torque bolts to specification and follow the torque sequence at beginning of the chapter ...

Page 104: ...gear I Install washer and bolt Use the Gear Holder PU 45838 Torque to specification 26 Use the Cam Gear Alignment Tool PU 45497 2 to align the teeth of the cam gear M Install the cam gear M with the Cam Gear Alignment Tool still in place onto the camshaft The timing marks on the camshaft gear should align with the keyway on the balance shaft gear NOTE If the timing mark on the camshaft gear does n...

Page 105: ...ST be installed DRY no lubricant during assembly Use of lubricants oil soapy water etc will not allow the seal to wear in and seal properly Do not touch seal surface or allow seal surface to come in contact with contaminates during installation Thoroughly clean parts tools and hands before installation NOTE To remove the water pump seal the gear stator housing must be removed The water pump seal c...

Page 106: ...e Back to Front Remove the tool 30 Carefully install the tapered end of the Crankshaft Seal Protection Tool PA 45658 through the paper side of the crankshaft seal Back to Front Leave the seal protector installed in the crankshaft seal Check the crankshaft seal lips to verify they have not been rolled or damaged 31 Before installing the gear stator housing cover install the Water Pump Seal Saver PA...

Page 107: ...er O to the crankcase with the cover bolts Torque bolts in proper sequence to specification Remove seal protectors from the shaft ends once secure NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 36 Install shaft seal with ceramic surface facing inward Gear Stator Housing Gasket T Gear Stator Hou...

Page 108: ...olts Torque bolts to specification 41 Install the wire hold down bracket T Install two new wire hold down bolts New bolts contain patch lock Torque bolts to specification following the proper bolt torque sequence Coat the stator wire grommet U with Nyogel Grease PN 2871329 NOTE Verify stator wires are routed properly under the wire hold down bracket T Water Pump Impeller Nut Torque 108 6 in lbs 6 ...

Page 109: ...e engine Install Oil System Priming Adapter PU 45778 into the oil plug hole Push 3 5 oz approx of Polaris 0W 40 into the adapter or until resistance is felt Remove the adapter Apply sealant to the plug threads Install the plug and torque to specification T Flywheel Nut Torque 65 7 ft lbs 88 9 50 Nm T Stator Housing Bolt Torque 96 3 in lbs 10 85 0 35 Nm 65 7 ft lbs 88 9 50 Nm 96 3 in lbs 10 85 0 35...

Page 110: ...starter bendix if removed 4 Install woodruff key Install the flywheel Install the flywheel washer and nut Torque the flywheel nut to specification 5 Inspect the mating surface around the gear stator housing cover and the crankcase for oil seepage If there is seepage between the mating surfaces then the gear stator housing cover must be resealed Clean the gearcase surfaces and reseal with a new gas...

Page 111: ...de of bolt head with engine oil Install head bolts C and torque to specification 4 Lubricate push rods D and install into lifters 5 Lubricate rockers E with engine oil 6 Verify pushrods are engaged in lifters 7 Install rockers Be sure that tab of fulcrum F is seated in head stand off Torque bolts to specification T Cylinder Head Bolt Torque Initial setting 35 4 ft lbs 47 5 5 5 Nm Allow to set for ...

Page 112: ...lean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 10 Install rocker cover Torque bolts to specification 11 Install thermostat J new O ring and thermostat housing Torque to specification 12 Install temperature sender K and torque to specification T Breather Bolt Toque 20 5 in lbs 2 5 0 55 Nm T Rocker Cover Bolt Torque 8...

Page 113: ...gine Runs But Will Not Idle Restricted carburetor pilot system Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate 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 speed Incorrect ignition timi...

Page 114: ...tion or kill switch circuit faulty Ignition poor connections in ignition system n timing incorrect Sheared flywheel key Valve sticking Cooling System Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket...

Page 115: ...iPerWash to clean away any remaining grime salts or oils 3 If the canisters are stained from oils or other fluids use fine steel wool with HPC Liquid Buff Cleaner and Polish to remove the stain 4 After removing the stains polish using Liquid Buff and a soft cloth 5 Repeat this procedure as often as desired to maintain the canister s finish NOTE Silencer removal requires replacement of the silencer...

Page 116: ...NOTES ENGINE 3 60 ...

Page 117: ...4 12 FUEL FILTER SERVICE 4 12 FUEL FILTER REPLACEMENT 4 12 FUEL INJECTORS 4 13 OPERATION OVERVIEW 4 13 FUEL INJECTOR SERVICE 4 13 FUEL INJECTOR REPLACEMENT 4 13 CRANKSHAFT POSITION SENSOR CPS 4 14 OPERATION OVERVIEW 4 14 CRANKSHAFT POSITION SENSOR TEST 4 14 CRANKSHAFT POSITION SENSOR CPS REPLACEMENT 4 14 TEMPERATURE BAROMETRIC AIR PRESSURE SENSOR T BAP 4 15 OPERATION OVERVIEW 4 15 TEMPERATURE AND ...

Page 118: ...e is extremely flammable and explosive under certain conditions EFI components are under high pressure Verify system pressure has been relieved before disassembly Never drain the fuel system when the engine is hot Severe burns may result Do not overfill the tank The tank is at full capacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine ...

Page 119: ...ength of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system Although every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring harness connector to the control unit or any i...

Page 120: ... Unit ECU 2 Intake Air Temperature Barometric Air Pressure Sensor T BAP 3 Crankshaft Position Sensor CPS 4 Fuel Injectors 5 Fuel Filter 6 Fuel Pump Tank Assy 7 Fuel Rail 8 Engine Coolant Sensor ECT 9 ThrottlePositionSensor TPS 10 Throttle Body 1 2 3 4 5 6 7 8 9 10 4 ...

Page 121: ...BAP 3 Crankshaft Position Sensor CPS 4 Fuel Injectors 5 2 Fuel Filters 1 located in tank 1 under front cab cover not pictured 6 Fuel Pump Regulator Gauge Sender Assembly located In tank as an assembly 7 Fuel Rail 8 Throttle Position Sensor TPS 9 Throttle Body 10 Wire Harness Assembly 11 Engine Coolant Temperature Sensor ECT 1 10 4 7 2 8 9 3 11 ...

Page 122: ...r removal 3 To install the line verify the connector and fuel tank nipple are clean and free of debris 4 Snap the fuel line back over the nipple and slide the locking mechanism back into place Verify the connector tabs snap back into place 1 Cap 2 Tank Vent 3 Tank Mount 4 Fuel Pump Tank Assembly 5 Frame 6 Protective Foil 1 2 3 4 5 6 Fuel Tank Fuel Filters 30 micron 10 micron Fuel Pump Pressure Reg...

Page 123: ...on of the fuel occurs each crankshaft revolution or twice for each 4 stroke cycle One half the total amount of fuel needed for one firing of a cylinder is injected during each injection When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor s...

Page 124: ...failure a rev limiting feature is programmed into the ECU If the maximum RPM limit 6500 is exceeded the ECU suppresses the injection signals cutting off the fuel flow This process repeats it self in rapid succession limiting operation to the preset maximum Sportsman 700 800 EFI RPM Limit Hard Limit Injector suppression occurs High 6500 Low 6500 Neutral 6500 Reverse 6500 Park 6500 Soft Limit Timing...

Page 125: ... replaced if determined to be faulty If a fuel delivery problem is suspected make certain the filters are not plugged that the pump is being activated through the ECU all electrical connections are properly secured the fuses are good and a minimum of 7 0 volts is being supplied If during starting the battery voltage drops below 7 0 volts the ECU will fail to operate the system 1 Remove the fuel te...

Page 126: ...orrect ECU operation by plugging in a known good ECU of the same model NOTE If the pump still does not operate replace the pump tank assembly Fuel Pump Tank Assembly Replacement NOTE All EFI unit utilize quick connect fuel lines NOTE The fuel pump cannot be replaced as an individual part the entire fuel pump and fuel tank is replaced as an assembly Refer to your parts book for the proper part numb...

Page 127: ... from spilling out the top inlet FUEL PUMP TANK INSTALLATION 1 Reinstall the pump tank assembly 2 Reconnect the sender wiring harness and route the harness properly Install the fuel line and tighten the fuel line clamp 3 Reinstall the two fuel tank mounting bolts at back of tank 4 Reinstall the PVT intake duct gas tank vent line front cab assembly and side panels NOTE Properly route the gas tank v...

Page 128: ...bly If it is faulty the pump assembly must be replaced Refer to the Fuel Pump Tank Assembly Replacement procedure FUEL FILTERS General Information NOTE All EFI units utilize quick connect fuel lines EFI Engines use a non serviceable high volume high pressure 30 micron internal fuel pump filter and a replaceable 10 micron in line fuel filter Fuel Filter Service In line filter replacement is recomme...

Page 129: ...ply voltage directly to the fuel injector s Excessive voltage will burn out the injector s Do not ground the injector s with the ignition on lnjector s will open turn on if relay is energized If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be internal past...

Page 130: ...tes a problem within this area test and correct as follows 1 Disconnect main harness connector from ECU 2 Connect an ohmmeter between the pin terminals A resistance value of 560Ω 10 at room temperature 20 C 68 F should be obtained If resistance is correct check the mounting air gap toothed ring gear damage runout etc and flywheel key 3 Disconnect speed sensor connector from wiring harness the conn...

Page 131: ...on the o ring to aid installation 3 Torque the retaining bolt to specification THROTTLE POSITION SENSOR TPS Operation Overview The throttle position sensor TPS is used to indicate throttle plate angle to the ECU Mounted on the throttle body and operated directly off the end of the throttle shaft the TPS works like a rheostat varying the voltage signal to the ECU in direct correlation to the angle ...

Page 132: ...ded with the TPS Test Adapter Harness PU 47082 or follow the steps below to check reference voltage Harness Test Insert black voltmeter probe into the Bk test port Connect the red meter probe into the R port and verify the voltage is 4 99 5 01 Vdc If this reading is low verify the 9 volt battery is good or try a new 9 volt battery Throttle Position Sensor Initialization NOTE The correct position o...

Page 133: ...the screw holding the TPS to the throttle body Rotate TPS until voltmeter reads 528 01 volts Retighten TPS mounting screw and verify the voltage did not change If changed repeat the previous steps STEP 2 Establishing correct flow Now that the zero offset voltage has been set you can now set the throttle body to the correct air flow value With voltmeter still attached to the TPS Test Adapter Harnes...

Page 134: ...or circuit is interrupted the fan will default to ON Engine Temperature Sensor Test To quickly rule out other components and wiring related to the ETS disconnect the harness from the ETS The fan should turn on and HOT should indicate on the instrument cluster This indicates all other components are working properly Refer to Chapter 10 for ETS testing Polaris dealers can also test the sensor by usi...

Page 135: ...0117 42 Engine Temperature Sensor Circuit Short To Ground Yes P0118 42 Engine Temperature Sensor Circuit Open or Short to Battery Yes P0107 45 Barometric Pressure Sensor Circuit Low Input Yes P0108 46 Barometric Pressure Sensor Circuit High Input Yes P1260 51 Injector 1 Open Load Yes P0261 51 Injector 1 Short Circuit to Ground Yes P0262 51 Injector 1 Short Circuit to Battery Yes P1263 52 Injector ...

Page 136: ... engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting incorrect Injector failure Poor Idle Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw set incorrect Throttle cable sticking improperly adjusted routed incorrectly Sym...

Page 137: ...4 21 FUEL INJECTION 4 EFI CIRCUIT Power On EFI CIRCUIT Crank Position Sensor ...

Page 138: ...4 22 FUEL INJECTION EFI CIRCUIT Fuel Pump EFI CIRCUIT Throttle Position Sensor ...

Page 139: ...4 23 FUEL INJECTION 4 EFI CIRCUIT Temperature Barometric Air Pressure Sensor EFI CIRCUIT Engine Temperature ...

Page 140: ...4 24 FUEL INJECTION EFI CIRCUIT Malfunction Indicator Light ...

Page 141: ...5 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 BLOCK INSTALLATION PROCEDURE 5 16 STEERING A ARM EXPLODED VIEW 5 17 A ARM REPLACEMENT 5 18 BALL JOINT REPLACEMENT 5 19 STEERING POST REMOVAL 5 20 STEERING POST ASSEMBLY 5 20 SUSPENSION 5 20 FRONT STRU...

Page 142: ...r 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 Mounting Bolt 35 48 Lower Wheel Bearing Carrier Bolt 50 68 Strut Rod Retaining Nut Top 15 21 Strut Casting Pinch Bolt 15 21 Tie Rod End Jam Nut 12 14 17 19 Tie Rod End Castle Nut 40 45 54 61 Tie Rod End ...

Page 143: ...up 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 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 ...

Page 144: ...tward 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 Installation 1 Open the front storage compartment 2 Pull up and outward on the front cover to remove the cover 3 To install the front cover insert the tabs of the front cover into the inserts of the cab M...

Page 145: ...ures 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 to the front and rear cabs See PLASTIC INSERT REMOVAL INSTALLATION for help 2 Remove the six screws B from the bottom of the foot well Remove the footwell 3 Reverse the removal procedures to install...

Page 146: ...emove 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 the outside of the storage box to the front fenders each side Front Storage T 25 Screws A Remove Bolts Remove Bolts T 25 Screws ...

Page 147: ... 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 front plastic bumper 7 Remove the remaining bolts and screws that secure the front bumper section to the frame Pull Out to Remove 1 Place Lip In Groove Groove Lip 2 Press in Tabs C D ...

Page 148: ... 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 Sportsman Rear Rack Removal Installation 1 Remove the six A T27 screws and two bolts B that secure the rear rack to the rear cab and frame 2 Lift the rear rack from the ATV Remove the two rack spacers C Fr...

Page 149: ...two 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 of the foot wells to the front cab 6 Remove the fuel cap and place a clean lint free shop towel into the tank neck to keep any debris from falling into the tank 7 The front cab should now slide back o...

Page 150: ...pulling 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 Remove the plastic inserts circled that secure the quarter panel to the rear footwell See PLASTIC INSERT REMOVAL INSTALLATION for information 3 Reverse the removal procedures to install the quarter pa...

Page 151: ...ar 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 out slightly on the top of the radiator screen 2 With the top free pull out on the bottom of the screen to remove the screen 3 To install the screen simply press the tabs on the screen back into the mo...

Page 152: ...sembly 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 Shields Front Cab Front Cover Front Cab Assembly ...

Page 153: ...TEERING 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 Footwell Support ...

Page 154: ... 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 Sportsman Only ...

Page 155: ...od 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 cluster connectors to instrument cluster Install top of pod onto bottom half making sure interlocking tabs mate properly Install two side Phillips screws Install one rear Phillips screw To adjust head...

Page 156: ...th 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 torque the 2 front bolts to specification 5 Install the rear bolts and tighten evenly Evenly torque the 2 rear bolts to specification NOTE There will be a slight gap on the backside of the blocks af...

Page 157: ...rod 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 reassembly Install with open end toward rear of machine 1 Always use new bolts upon reassembly 1 1 25 30ft lbs 35 41 Nm Steering Post Steering Post Arm 12 14 ft lbs 17 19 Nm A 30 ft lbs 41 Nm 40 45 ft lbs 5...

Page 158: ... 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 towardrear of machine Bend both ends in opposite directions around nut T A Arm Bolt Torque 30 ft lbs 41 4 Nm WARNING The locking features on the existing bolts were destroyed during removal DO NOT re...

Page 159: ...turn 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 cap and attach puller guide using short bolts provided in the kit 15 Insert new ball joint K into driver L 16 Slide ball joint driver assembly into guide 17 Apply heat to ease installation 18 Drive ...

Page 160: ...and 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 strut pivot assembly 3 Compress spring using any commercially available spring compressor tool and remove the spacer nut 4 Remove coil spring and collapse strut cartridge 5 Remove two pinch bolts from st...

Page 161: ...ut 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 ft lbs 25 Nm Clamp 15 ft lbs 21 Nm ...

Page 162: ...Assembly 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 1 1 35 ft lbs 48 Nm Bushing Orientation 50 ft lbs 68 Nm ...

Page 163: ...SION 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 Control Arm Pivot Bracket ...

Page 164: ...5 24 BODY STEERING SUSPENSION X2 Torsion Bar Exploded View Linkage Bushing Stabilizer Bar Torsion Mount Linkage Asm Bushing Stabilizer Bushing ...

Page 165: ...5 25 BODY STEERING SUSPENSION 5 X2 CARGO BOX Exploded View ...

Page 166: ...he 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 Carefully pull out the red locking tab on the connector 5 Once the red tab is pulled out press in on the black tab and pull out to disconnect harness A CAUTION Use caution when disconnecting the smaller li...

Page 167: ...x 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 steps to reinstall the cargo box Refer to the standard fastener torque values in Chapter 1 during assembly See Standard Torque Specifications on page 1 12 Clip Pin ...

Page 168: ...5 28 BODY STEERING SUSPENSION X2 SEAT ASSEMBLY Exploded Views ...

Page 169: ...t 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 down into place to serve as the passenger seat bottom 5 Lift the latch on the passenger backrest to set the proper backrest height desired by the passenger A B Passenger Backrest Driver Seat Backrest...

Page 170: ...eps 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 latch for the passenger seat bottom and lock it in the upright position as shown below 3 Remove the two screws retaining the passenger backrest 4 Remove the two pivot pins holding the backrest to the ...

Page 171: ...4 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 MOVEABLE SHEAVE BUSHING INSPECTION 6 18 DRIVE CLUTCH BUSHING SERVICE 6 18 ONE WAY CLUTCH INSPECTION DRIVE CLUTCH 6 20 DRIVE CLUTCH REASSEMBLY 6 20 EBS DRIVEN CLUTCH SERVICE 6 22 DRIVEN CLUTCH DISASSE...

Page 172: ...ller 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 Bushing Replacement Tool Kit 2871025 Clutch Compression Tool Extensions PS 45909 COMPONENT FT LBS IN LBS NM Drive Clutch Retaining Bolt 40 54 Driven Clutch Retaining Bolt 17 23 PVT Inner Cover Bolts ...

Page 173: ... 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 Cover Seal NON EBS One Way Clutch Standard Models Deluxe Models EBS ...

Page 174: ...rew 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 Retaining Ring 17 Retaining Ring 18 Inner Spider Plate 19 Spider Dampener 20 Clutch Roller DELUXE EBS ...

Page 175: ...y 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 Clutch Shaft Spacer Washer Sheaves Clutch Rollers Bearing Retaining Rings ...

Page 176: ...rive 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 driven clutch sheaves As engine RPM and horsepower increase the load from the drive belt increases resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward int...

Page 177: ... 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 Clutch Alignment on page 6 14 2 Drive and Driven Clutch Rollers and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs See Drive C...

Page 178: ...ponents 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 free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one ...

Page 179: ... 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 understanding the effects they have on belt to sheave clearance clutch balance engagement and shifting characteristics NLA NLA 698 ...

Page 180: ...sion 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 and procedures will vary Refer to the appropriate parts manual for proper fasteners and fastener placement 1 Remove seat 2 Remove or loosen cab and footwell fasteners as necessary to gain access to PV...

Page 181: ...ngine 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 side Surfaces must be clean to ensure adhesion of silicone sealant 4 Reinstall cover and tighten rear cover bolts just enough to hold it in place 5 Fit lip of inner cover seal A to engine Install se...

Page 182: ... 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 part numbers are easily read 3 To remove drive belt apply brake pull upward and rearward on belt while turning the back moveable driven sheave clockwise to open driven clutch sheaves Pull out and do...

Page 183: ... 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 Troubleshooting Chart at the end of this chapter for possible causes DRIVE BELT INSTALLATION NOTE Be sure to position belt so part number is easily read Verify new belt is seated properly in the clutches bef...

Page 184: ...es 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 can be removed to decrease the distance at point A Clutch Offset IMPORTANT Inspect clutch alignment and center distance before adjusting offset Offset is correct when rear of tool contacts rear of in...

Page 185: ... 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 Specifications for spring inspection Spider Removal 1 Remove the limiter nut using the Clutch Spider Nut Socket PN 2870338 Install clutch in holding fixture and loosen the spider counterclockwise using Clutch Spi...

Page 186: ...ust 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 buttons can and should be used in all ATV clutches if the hollow roller pin is changed to a solid roller pin NOTE Rubber side of the button is positioned toward the solid roller pin It is recommended to...

Page 187: ...pection 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 sheave spacer sleeve 1 and the thrust washer 2 Visually inspect the washer for damage Measure the thickness and compare to specification Replace if worn or damaged Button to Tower Clearance 000 001 ...

Page 188: ...ect 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 mm Shaft Diameter Standard 1 3745 1 375 Service Limit 1 3730 In mm PTFE Washer Thickness Standard 030 76mm Service Limit 025 64mm Moveable Sheave Bushing Inspection Replace the cover bushing if more ...

Page 189: ...pear 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 bushing from tool and discard Drive Clutch Bushing Installation 1 Place main adapter Item 8 on puller 2 Apply Loctite 609 evenly to bushing bore inside moveable sheave 3 Set bushing in place on sheav...

Page 190: ... 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 one way clutch clockwise as viewed from the cover plate side The clutch should rotate on the shaft with only slight amount of drag Verify there is no binding or rough spots When rotated counterclockw...

Page 191: ...age 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 Reinstall clutch spring 8 Reinstall cover aligning bosses on the tower and cover Torque cover bolts evenly to specification CAUTION Verify spider spacer washers are fully seated in the recessed area of t...

Page 192: ...ts 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 into Clutch Compression Tool PN 8700220 Using Compression Extensions PN PS 45909 Press down on top of the spider assembly compressing the spider onto the shaft Remove snap ring A and slowly release th...

Page 193: ...Inspect 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 the inner sheave 10 Pull out the clutch roller pins L and rollers M 11 Press the shaft and bearing out of the outer sheave using a press E D H G F I J K K M L Press Shaft Bearing Out Inspect Bearing ...

Page 194: ...stalling 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 bushing until tiny smoke tailings appear 4 Flip sheave over so bushing faces downward and install onto puller 5 Install bushing tool Item 2 6 Install left hand nut C and spacer onto puller rod and tighten...

Page 195: ...em 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 straight into bore Continue until bushing is seated 8 Remove nut C from puller rod and set aside 9 Remove installation tool and clutch sheave from puller EBS DRIVEN CLUTCH REASSEMBLY 1 Press a new bearin...

Page 196: ... 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 faces downward when the shaft side is laying flat on the bench 7 Install the spring pins C to secure the roller pins Install until flush with sheave surface Align X s A B Flat Side Down C ...

Page 197: ...E 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 8700220 Using Compression Extensions PN PS 45909 Press down on the top of the spider assembly pushing the spider onto the shaft 14 Slowly compress the spider into place If the spider appears to bind while ...

Page 198: ...arker 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 remove cover plate 3 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing 4 Inspect area on shaft wh...

Page 199: ...r 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 must 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 ClutchHoldingFixt...

Page 200: ...mooth 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 three with new bolts NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See roller inspection see Roller Pin and Thrust Washer Inspection Button to Tow...

Page 201: ...nd 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 center of sheave 8 Install nut onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Using a hand held propane torch apply heat around outside of bushing unti...

Page 202: ...over 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 and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and cl...

Page 203: ...the 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 misalignment will alter clutch balance Inverting the clutch while initially tightening the spider will help position the washers T Spider Limiter Nut Torque 15 ft lbs 20 Nm Spacer Washers Engine Rotation Nut on...

Page 204: ... 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 cracked 2 Inspect the inner sheave helix E and spring retainer F for signs of wear 3 Remove the inner spring retainer F from the inner sheave and inspect for signs of wear CAUTION Wear eye protection when ...

Page 205: ...tall 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 spring 4 Install the outer retainer on top of spring 5 Using special tool PN 8700220 compress the outer retainer onto the shaft and install the snap ring Sheave Bushing Inspection Replace bushing if m...

Page 206: ...to low ambient temperatures Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Continuous operation at the point of engagement initial vehicle movement increases PVT tem...

Page 207: ...en 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 cleaner install new belt Harsh drive clutch engagement Drive belt worn too narrow Replace belt Excessive belt sheave clearance with new belt Perform belt sheave clearance adjustment with shim washers...

Page 208: ... 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 repair as necessary Engagement erratic or jerks Thin spots on belt worn belt Replace belt Refer to belt burnt troubleshooting and instruct operator Drive clutch bushings stick Inspect and repair clu...

Page 209: ...2 DISASSEMBLY INSPECTION 7 13 REASSEMBLY INSPECTION 7 17 SETTING RING GEAR BACKLASH 7 18 FRONT GEARCASE DIAGNOSIS 7 19 GEARCASE INSTALLATION 7 20 FRONT GEARCASE ACTIVE DESCENT CONTROL DELUXE MODELS 7 21 ADC GEARCASE EXPLODED VIEW DELUXE MODELS 7 21 OPERATION 7 22 ADC COIL TESTING 7 23 ADC DIFFERENTIAL HYDRAULIC CIRCUIT BLEEDING 7 23 DISASSEMBLY INSPECTION 7 23 ADC GEARCASE PISTON REPLACEMENT PROCE...

Page 210: ...case Mount Bolts 30 41 Rear Gearcase Bolts 25 34 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 TOOL DESCRIPTION 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers 2870772 1 3 4 Straight Wrench PA 48542 ADC Gearcase Piston Installation Tool GEARCASE DESCRIPTION Centralized Hilliard...

Page 211: ...rom 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 pivoting front drive shaft downward until it clears strut assembly ...

Page 212: ...otter 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 loses all of the grease CV joint failure will occur Replacement 1 Remove wheel brake caliper and wheel hub Refer to FRONT DRIVE AXLE REMOVAL earlier in this chapter for procedure 2 Remove cotter pin and...

Page 213: ...ype 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 over the splined shaft then slide tap the CV joint into the splines of the axle 10 Add grease through large end of boot 11 Install a new boot onto the axle shaft and fill the CV joint and boot with the ...

Page 214: ...earings 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 movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged Assembly 1 Support bottom of hubstrut housi...

Page 215: ...oosening and or removal of rear gearcase mounting bolts may be required to gain necessary clearance for propshaft removal See REAR GEARCASE on page 7 39 U JOINT Disassembly 1 Remove internal or external snap ring from all bearing caps NOTE If yoke or bearing is removed cross bearing must be replaced Note orientation of grease fitting if equipped and mark inner and outer yoke for correct re positio...

Page 216: ...rd 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 Continually check for free movement of bearing cross as bearing caps using a suitable arbor fully seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assemble...

Page 217: ...st 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 freely in all directions without binding If the joint is stiff or binding tap the yoke lightly to center the joint until it pivots freely in all directions ...

Page 218: ...clip 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 Assy Cross Bearing Kit Prop Shaft O Ring Yoke Prop to Transmission Yoke Front Gearcase Yoke Rear Gearcase Prop Shaft Yoke Prop to Transmission ...

Page 219: ... 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 Bushing 1 19 Output Cover Asm 1 9 Magnetic Drain Plug 1 20 Connector Asm 1 10 Oil Seal 2 21 Thrust Button Asm 1 11 Plug Cap 1 22 Set Screw 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 16 6 1 10 20 21 22 ...

Page 220: ...gear 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 shaft overdrives the front gearcase input The rollers are forced outward disengaging the AWD The vehicle is now back to rear wheel drive until the next loss of rear wheel traction Gearcase Removal 1 S...

Page 221: ...curing 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 both the remaining CV shaft and propshaft from the gearcase Replace the circlips on the CV shaft ends prior to reassembly Disassembly Inspection 1 Drain and properly dispose of used oil Remove any metal...

Page 222: ...output 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 damage Replace component if found to be worn or damaged 5 Remove the roll cage assembly rollers and ring gear Thrust Bearing Armature Plate Output Hub Assembly ...

Page 223: ...ust 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 This surface must be clean and free of nicks burrs or scratches Inspect the H springs but do not remove them from the roll cage 10 Inspect the armature plate for a consistent wear pattern Uneven wear ...

Page 224: ...ad 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 Remove the snap ring retaining the input shaft assembly 14 Remove the input shaft assembly Inspect the pinion gear C for chipped broken or missing teeth Inspect the input shaft bearing D for signs of wear...

Page 225: ...by 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 bearing snap ring and input cover with new o ring Torque bolts to specification 5 Install the LH output hub A into the gearcase housing The output hub should spin freely 6 Install the RH output hub B...

Page 226: ...e main gearcase NOTE Verify the square O ring 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 Laythegearcaseonthesidewiththeoutputcoverfacingup Setting Ring Gear Backlash NOTE Ring gear backlash is set at the factory No adjustment is required unless the front cover is replaced or the back lash pad screw is rem...

Page 227: ...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 Check the minimum battery voltage at the Grey Brown White wires that feed the hub coil wires There should be a minimum of 11 80 12 0 Volts present for proper operation 3 Inspect the armature plate for ...

Page 228: ...Cover 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 roll cage sliding surfaces Gearcase Installation 1 To install gearcase reverse removal procedures Use new roll pin in front prop shaft 2 Torque mounting bolts in skid plate to 30 ft lbs 41 Nm 3 Add ...

Page 229: ...p Assembly 1 5 Bushing 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 Cover Bracket 1 26 Armature Plate 1 11 Gear Case Sub Assembly 1 27 Pinion Cover Assembly 1 12 Hose Clamp 2 28 Retaining Ring 1 13 Hub Sub Assembly 2 29 Pinion Gear Assembly 1 14 Plastic Clip 2 30 Fill Plug ...

Page 230: ... 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 armature plate attracts the unsplined eccentric cam 3 which begins to turn with the input shaft The eccentric cam drives a hydraulic piston pump assembly 5 The pressure created by the pump assembly forces...

Page 231: ... 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 before oil level falls below minimum fill line Refilling empty reservoir will result in air pockets becoming trapped NOTE If empty reservoir is encountered filling of fluid is still possible Verify air i...

Page 232: ...rea If plates 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 are key indicators of clutch pack failure Replace clutch as an assembly if found to be worn or damaged NOTE Locating pins holes circle aid installation Note for reassembly 6 Remove the armature plate Inspect t...

Page 233: ...roller 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 burrs or scratches Remove and inspect the H springs 4 Replace any components as required 13 Inspect the armature plate for a consistent wear pattern Uneven wear of the armature plate indicates a warpe...

Page 234: ... 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 assembly 16 Inspect the magnetic coil 1 and bushing in the input cover plate assembly Replace the input cover seal 17 Remove the splined armature plate 1 18 Remove the eccentric cam assembly Inspect the c...

Page 235: ...ent 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 piston up and out of the case See photo 2 Repeat procedure for the other piston See photo 3 Remove and discard the inner and outer o rings from the piston assembly NOTE Never re use o rings Always rep...

Page 236: ...gnment 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 piston is fully seated and located in the pin bosses when the piston surface is just below the cavity edge 7 Repeat procedure for the other gearcase half NOTE Verify that the o rings are seated prope...

Page 237: ...ll 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 assembly 1 6 Install the splined armature plate 1 7 Install the input shaft cover assembly bolts and bracket Torque to specification 1 2 T Input Cover Bolt Torque 7 11 ft lbs 9 4 14 9 Nm 1 1 ...

Page 238: ... 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 gear 3 NOTE Align locating pins holes for installation 11 Install the spacer NOTE Align locating pins holes for installation arrow 12 Install the armature plate Verify the armature plate tabs align with tab rec...

Page 239: ...allation 15 Place cover assembly on Install bolts arrows retaining the outer cover plate assembly and torque to specification 16 Install a new passage o ring dotted circle on the gearcase and install the piston pump assembly Torque the screws to specification NOTE See Gearcase Installation on page 7 20 1 2 T Input Cover Bolt Torque 7 11 ft lbs 9 4 14 9 Nm T Pump Assembly Screw Torque 17 23 in lbs ...

Page 240: ... 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 frame with a piece of wire 8 Remove hub nut domed washer and flat washer 9 Remove hub 10 Remove upper control arm bolt as shown A B C ...

Page 241: ...e 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 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 movement and minimal mo...

Page 242: ...ring 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 housing 3 Install and torque both lower control arm bolts CAUTION Use an arbor press only on the outer race to avoid bearing damage T Upper Control Arm Bolt Torque 35 ft lbs 48 Nm ...

Page 243: ...que 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 carrier bolt Tip hub outward and remove shaft from carrier 3 Pull sharply outward to remove shaft from transmission Install a new lock ring upon assembly T Lower Control Arm Bolt Torque 50 ft lbs 68...

Page 244: ...locate 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 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 joint from shaft Tabs f...

Page 245: ... 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 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 spher...

Page 246: ...h 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 is cleaned 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 plac...

Page 247: ...or sharp tools to remove or to install boot clamps Be sure joints are thoroughly 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 GEARCASE Removal 1 Place ATV on a level surface and place transmission in PARK 2 Loosen both rear wheel nuts 3 Loosen bo...

Page 248: ... wear broken or chipped teeth Spin the bearing to check the ball bearings for smoothness Replace the bearing if needed 6 Remove the input shaft cover and the pinion shaft from the gearcase housing See next page 7 Inspect the ring gear for abnormal wear broken or chipped teeth Spin the bearing to check the ball bearings for smoothness Replace the bearing if needed Thrust Button Shims ...

Page 249: ...d torque the cover bolts to specification 4 Install the original shim s thrust button and thrust button shims into the gearcase cover 5 Apply Crankcase Sealant PN 2871557 to surface of case and install cover bolts Install the gearcase cover onto the gearcase housing Torque the cover bolts in a criss cross pattern to specification T Input Cover Bolt Torque 25 ft lbs 34 Nm T Cover Bolt Torque 25 ft ...

Page 250: ... shaft splines is recommended 3 Torque the gearcase mounting bolts to specification 4 Re install CV shafts hubs carrier bolts etc and torque to specifications 5 Re install gearcase vent line 6 Refill the rear gearcase with Polaris Premium Gearcase Lubricant PN 2871653 Refer to the REAR GEARCASE LUBRICATION procedure in Chapter 2 T Drain Fill Plug Torque 14 18 ft lbs 19 24 Nm T Gearcase Mounting Bo...

Page 251: ...7 43 FINAL DRIVE 7 Rear Gearcase Exploded View ...

Page 252: ...NOTES FINAL DRIVE 7 44 ...

Page 253: ...TRANSMISSION 8 1 CHAPTER 8 TRANSMISSION 8 SPORTSMAN 8 3 8 18 SPORTSMAN X2 8 19 8 38 ...

Page 254: ...NOTES TRANSMISSION 8 2 ...

Page 255: ...NSMISSION EXPLODED VIEW 8 4 SPORTSMAN 700 800 EFI TRANSMISSION 8 4 SPECIFICIATONS 8 6 TORQUE SPECIFICATIONS 8 6 LUBRICANT CAPACITY 8 6 TRANSMISSION SERVICE 8 6 TRANSMISSION REMOVAL 8 6 DISASSEMBLY 8 7 ASSEMBLY 8 12 TRANSMISSION INSTALLATION 8 18 TROUBLESHOOTING 8 18 ...

Page 256: ...8 4 SPORTSMAN TRANSMISSION TRANSMISSION EXPLODED VIEW Sportsman Transmission ...

Page 257: ...ing 48 3 6 Face Engagement Dog 15 1 Shift Drum 49 2 Retaining Ring 16 1 Retaining Ring 50 2 Washer 17 1 6 Pin Rotary Switch 51 1 33T 6 Face Gear 18 1 O ring 52 3 Needle Split Cage Bearing 19 1 Detent Star 53 1 Reverse Shaft 20 1 Lockout Disc 54 1 24T 6 Face 21 1 16T Sector Gear 55 1 Washer 22 2 Hex Nut 56 1 28T 6 Face Gear Includes 38 61 67 23 4 Dowel Pin 57 1 51T Mid Output Helical Gear 24 1 Plai...

Page 258: ...t transmission vent line 6 Drain transmission lubricant 7 Disconnect shift linkage rod end from transmission bellcrank 8 Disconnect gear position switch harness 9 Remove auxiliary brake mounting bracket from frame and secure out of way for transmission removal 10 Remove PVT outer cover both drive and driven clutch and inner PVT cover refer to Clutch Chapter 6 Table 8 1 Torque Specifications COMPON...

Page 259: ...pshaft from the transmission shaft 13 Remove left side transmission bracket rear bracket and lower right bracket bolt 14 Remove front transmission to engine mount bolts See illustration 15 Remove transmission from right side of frame Disassembly 1 Place the bellcrank in neutral position 2 Remove the nut and washer that secure the bell crank Remove the bellcrank 3 Remove the e clip and then remove ...

Page 260: ...ar for reassembly 6 Mark the shift lockout disc this will indicate which side of the disc faces outward during assembly Remove the shift lockout disc NOTE It may be helpful to place a mark just above the keyed spline Note the raised edge on the detent gear for reassembly 7 Remove the shift shaft and detent lever 8 Note the timing marks on the shift gears Remove the shift gears from the case NOTE Y...

Page 261: ...gear cluster on a flat surface and inspect the components 11 Remove the shift forks from the assembly Note the correct position of each fork 12 Remove the bearing from the reverse shaft using a puller 13 Remove the park lock engagement dog Remove the wave spring and reverse engagement dog 14 Remove the bearing from the input shaft with a puller Engagement Dogs ...

Page 262: ...e low gear 33T and the needle bearing 17 Remove the reverse gear shaft 18 Remove the rest of the bearings from the shafts 19 Use a press to remove the gear from the shaft 20 Make note of the direction of the gear and hub location 21 Remove the gear split bearing and washer from the reverse shaft ...

Page 263: ...s 23 Remove the snap ring washer gear and split bearing 24 Remove bearing and the helical gear 25 Remove the pinion shaft retainer plate and the pinion shaft 26 Remove the front housing cover screws 27 Remove the front housing cover shim thrust button and thrust button shim ...

Page 264: ...ransmission case IMPORTANT New seals should be installed after the transmission is completely assembled 34 Inspect bearings for smooth operation Check for excessive play between inner and outer race Assembly 1 Reinstall the chain onto the front output shaft and rear output shaft 2 Install front and rear output shafts into the case 3 Before installing the cover make sure the sealing surfaces are cl...

Page 265: ...y Loctite 262 Red PN 2871951 to screw threads and torque screws to specification 9 Install the a new needle bearing the 24T reverse sprocket washer and a new snap ring Install the shift dogs and wave spring Install the washer a new needle bearing and the high gear Install the press fit gear and ball bearing NOTE Install a new snap ring at this time When installing the new snap ring open the the sn...

Page 266: ... dogs are installed onto the shaft place the wave springs into the spring groove Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case NOTE Use caution when installing the fork as the spring can easily fall out NOTE Installing the shift rail will aid in keeping the shift forks shift dogs and the springs in place 15 Carefully install the ...

Page 267: ...d that the shift rail is seated into the pocket on the backside of the case 20 Install the helical gear and bearing onto the pinion shaft 21 Clean the mating surfaces of the case and cover Apply Crankcase Sealant PN 2871557 to the mating surfaces Be sure the locating pins knock pipes are in place Reinstall cover LH mounting bracket and torque bolts in a criss cross pattern in 3 steps to specificat...

Page 268: ... 26 Install the detent pawl and spring Install a new o ring onto the shift shaft after the detent pawl is assembled to the shaft Place a small amount of grease on the small o ring on the shift shaft and on the detent star Grease the o ring on the end of the shift drum 27 Apply Crankcase Sealant PN 2871557 onto the cover and case mating surfaces Install the cover and hand tighten all of the bolts 2...

Page 269: ...tall transmission from right side of vehicle 2 Align output shafts to propshaft yokes and roll pin holes 3 Slide output shafts into propshaft yokes and insert roll pins 4 Position transmission in frame 5 Loosely install left side and rear mounting brackets 6 Loosely install lower right bracket bolt 7 Loosely install front mounting bolts 8 Install PVT back cover bolts and driven clutch and torque t...

Page 270: ...adjustment and rod end positioning Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting linkage rod from transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions pr...

Page 271: ...W 8 21 SPECIFICATIONS 8 22 TORQUE SPECIFICATIONS 8 22 SPECIAL TOOLS 8 22 LUBRICATION 8 22 TRANSMISSION SERVICE 8 22 GEAR SELECTOR REMOVAL 8 22 TRANSMISSION REMOVAL 8 22 TRANSMISSION INSTALLATION 8 24 TROUBLESHOOTING CHECKLIST 8 26 TRANSMISSION DISASSEMBLY 8 26 TRANSMISSION ASSEMBLY 8 31 TRANSMISSION FRONT OUTPUT SHAFT BACKLASH PROCEDURE 8 32 ...

Page 272: ...8 20 Sportsman X2 Transmission TRANSMISSION EXPLODED VIEWS X2 Transmission Exploded View 262 242 THREAD LOCKING AGENT FOR ALL FT LBS FASTENERS THREAD LOCKING AGENT FOR INCH LBS FASTENERS ...

Page 273: ...8 21 Sportsman X2 Transmission 8 242 262 262 262 262 262 ...

Page 274: ...8 22 Sportsman X2 Transmission X2 Mounting Exploded View x2 x3 x4 x4 x2 x1 x1 x1 ...

Page 275: ...smission 5 Disconnect transmission vent line A 6 Disconnect shift linkage rod end B from transmission bellcrank C 7 Remove PVT outer cover drive and driven clutches and the inner PVT cover refer to Chapter 6 COMPONENT FT LBS IN LBS NM Transmission Case Bolts 25 30 36 43 Bell Crank Nut 12 18 17 26 Transmission Fill Drain Plug 20 25 29 36 Trans Mounting Bolts 40 57 Gear Sector Cover 8 12 11 17 Oil D...

Page 276: ...ove all fasteners X attaching the torsion mount and completely remove the mount Z from the ATV 12 Remove both upper control arms I Refer to Chapter 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 support brackets L completely from the ATV 16 Lift and r...

Page 277: ...l upper rear and middle support bracket bolts circled to specification 5 Install the upper control arms Refer to Chapter 5 for procedures and torque specifications 6 Reconnect the torsion bar to both lower control arms Torque to specification 7 Install both upper shock absorber mounts and torque to specification 8 Apply anti seize to splines of rear drive shafts and insert drive shafts into carrie...

Page 278: ... Chapter 5 14 Reconnect the differential speed sensor and gear selection switch connectors 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 Lubricant to the proper level See Chapter 2 for proper fill procedures and Torque Specifications Troubleshooting ...

Page 279: ... sector 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 Remove the detent star 8 Note how the detent star fits onto the splined shaft and the raised edge facing outward for reassembly 8 Remove the lockout disc 9 Note the raised edge facing outward for rea...

Page 280: ...lide 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 from the opposite side until it tips toward the output gear 19 The differential gear is connected to the shift fork and must slide backwards to clear the fork arms once the chain is removed 14 Remove ...

Page 281: ...t up 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 reverse shaft 19 Remove the retaining ring and washer from the reverse shaft 20 Remove the bearing from the input shaft using a bearing puller 21 Remove the 33T gear 3 and needle bearing 2 from the ...

Page 282: ... disassemble 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 T27 hex socket or driver 28 Mark the snorkel tube and case with a white pen or marker This is used to ease reassembly of the gearcase 4 REVERSE SHAFT Towards Inside of Case 5 6 7 8 9 CAUTION Use ...

Page 283: ...ond 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 snorkel shaft out 11 Front Drive Snorkel Assembly A O ring B Seal C Retaining Ring D Retaining Ring E Spacer F Ball Bearing G Snorkel tube H Retaining Ring I Ball Bearing J Snorkel Shaft A A B E D ...

Page 284: ...or 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 damage chips or abnormal worn teeth 4 Install 2 new O rings onto the snorkel tube Apply a white lithium grease onto the O rings and threads of the snorkel tube 5 Install the snorkel shaft assembly into the gearcas...

Page 285: ... 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 down into the gearcase at the snorkel lock screw hole opening Photo 2 to reference your starting point Next slowly rotate the snorkel tube counterclockwise Photo 3 counting the number of notches passing through the thread hole as you rotate th...

Page 286: ...embly 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 8 12 ft lbs 11 17 Nm Input Shaft Assembly A Ball Bearing B Input Shaft C Silent Chain A A B C REVERSE SHAFT Towards Inside of Case A Ball Bearing B Engagement Dog C Retaining Ring D Washer E Gear F...

Page 287: ...n if the measurement is longer than the service limit 8 The shift drum C reverse shaft D input shaft E and output gear assembly must 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 on it s side hold the gear cluster assembly and output assembly to...

Page 288: ...e to the angle of entry Install the differential sliding geardog onto the shift fork arms at the same time the silent chain is installed The differential gear bearing may be lightly tapped into place The output seal can be installed once the assembly is in place 13 Tensioner Installation NOTE Case halve mating may be difficult due to tensioner pressure on the drive chain during installation Releas...

Page 289: ...NOTE Case halve mating may be difficult due to tensioner pressure on the drive chain during installation Release tension at the ratcheting cam to aid case half installation Release the tensioner spring after the case halves are mated but not yet touching 16 Place a small amount of grease PN 2871551 into the pocket before installing the sector gear Tensioner Assembly Top View Forward Spring Leg Ten...

Page 290: ...ar J Install a new O ring onto the shift shaft Apply a small amount of grease onto the O rings and end of the shift drum 20 Install the compression spring K 21 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and case mating surfaces Install the cover and torque the bolts to specification 22 Install the bellcrank onto the shift shaft Note the key splined on the bellcrank and shaft Install ...

Page 291: ...C 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 SPORTSMAN REAR PAD REMOVAL 9 19 SPORTSMAN REAR PAD INSTALLATION 9 20 BRAKE BURNISHING PROCEDURE 9 20 X2 REAR CALIPER 9 21 REMOVAL 9 21 INSPECTION 9 22 REASSEMBLY 9 22 SPORTSMAN REAR CALIPER 9 23 REMOVAL AN...

Page 292: ...4 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 Thickness 150 165 3 81 4 19 mm 140 3 556 mm Brake Disc Thickness Variance 002 051 mm Brake Disc Runout 010 254 mm REAR BRAKE CALIPER X2 ONLY ITEM STANDARD SERVICE LIMIT Brake Pad Thickness 298 7 6 m...

Page 293: ... 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 5 Dual Input Master Cylinder and Bleed Screw 25 30 in lbs 2 8 3 4 Nm 6 Front and Rear Caliper Bleed Screws 36 60 in lbs 4 07 6 78 Nm 6 5 ...

Page 294: ...an 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 Screws 7 in lbs 0 79 m ...

Page 295: ...r 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 Screw C Caliper Asm D Boot E Caliper Seals F Piston G Caliper Mount H Brake Pads A B C D E F G H ApplyPolarisDOT approved Brake Fluid to Component 3 3 ...

Page 296: ...n 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 l...

Page 297: ...necessary 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 temperature of the brake fluid to drop which can lead to brake fade and the possible loss of control BRAKE NOISE TROUBLESHOOTING POSSIBLE CAUSE REMEDY Dirt dust or imbedded material on pads or disc Sp...

Page 298: ...the 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 or air may be drawn into caliper 8 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir 9 Tighten bleeder scre...

Page 299: ...e 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 removing the brake line banjo bolt Installation 1 Install master cylinder on handlebars Torque mounting bolts to specification Torque the inner bolt first as indicated in the illustration below T Master C...

Page 300: ...ver 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 Pad Removal 1 Elevate and support the of the ATV 2 Remove the wheel 3 Loosen pad adjuster screw 2 3 turns 4 Remove caliper from mounting bracket T Banjo Bolt Torque 15 ft lbs 21 Nm Torque to 15 ft lbs ...

Page 301: ...nto 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 worn beyond the service limit Assembly 1 Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease PN 2871423 and install rubber dust boots In mm Front Brake Pad Thickne...

Page 302: ...e 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 reduce noise NOTE Front Wheel Nut Torque Refer to Chapter 2 Brake Burnishing Procedure Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool...

Page 303: ... 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 Install disc on hub 5 Install new bolts and tighten to specification In mm Brake Disc Thickness Service Limit 140 3 556 mm In mm Brake Disc Thickness Variance Service Limit 002 051 mm between measur...

Page 304: ...slip 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 brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur Clean Components ...

Page 305: ...section 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 Coat piston with clean Polaris DOT approved Brake Fluid C Install piston D with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate ...

Page 306: ...e 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 Perform brake bleeding procedure as outlined earlier in this chapter 9 Install wheels and torque wheel nuts to specification Refer to Chapter 2 T Brake Caliper Mounting Bolt Torque 18 ft lbs 24 Nm 15 ft l...

Page 307: ...aliper 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 port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Push caliper mounting bracket inward and slip outer brake pad past ...

Page 308: ...12 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 counterclockwise 6 Verify fluid level in reservoir is up to the MAX line inside reservoir and install reservoir cap 7 Install wheel s and torque wheel nut s 8 It is recommended that a burnishing proce...

Page 309: ... 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 the brake pads from the caliper 7 Clean the caliper with brake cleaner or alcohol 8 Measure the thickness of the pad material Replace pads if worn beyond the service limit In mm Rear Brake Pad Thickn...

Page 310: ...commended 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 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficiently during the procedure Do not allow pads or disc to become hot or warping may result Repeat this procedure 10 times W...

Page 311: ...unting 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 body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injur...

Page 312: ...section 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 Coat piston with clean Polaris DOT approved Brake Fluid C Install piston D with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate ...

Page 313: ...ws 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 the brake pads D 5 Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers 6 Remove seals and O rings Clean the O ring grooves 7 Clean disc caliper body and pistons wi...

Page 314: ... 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 in groove Tighten the caliper anvil bolts and then torque the anvil bolts evenly to specification 3 Install brake pads in caliper body with friction material facing each other Install the slide pins...

Page 315: ... 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 disc thickness at 8 different points around perimeter of disc Replace disc if worn beyond service limit 3 Mount dial indicator and measure disc runout Replace the disc if runout exceeds specification...

Page 316: ...AR 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 J Banjo Fitting ...

Page 317: ...ere 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 gain access to the rear master cylinder 2 If required remove the rear brake line from the master cylinder Use a suitable container to catch the brake fluid Dispose of brake fluid properly 3 Remove the ...

Page 318: ...nder 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 brake bleeding procedures as outlined in this chapter T Master Cylinder to Frame Bolt Torque 8 ft lbs 11 Nm T Banjo Bolt Torque 15 ft lbs 21 Nm T Flare Stye Brake Line Torque 12 15 ft lbs 16 20 Nm 15 ft...

Page 319: ...c 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 or components Improper clearance between lever and switch Lever Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port pl...

Page 320: ...NOTES BRAKES 9 30 ...

Page 321: ...5 OPERATION OVERVIEW 10 15 DIAGNOSING SYSTEM FAILURES 10 15 COOLING SYSTEM COMPONENTS 10 16 FAN CONTROL CIRCUIT OPERATION TESTING 10 16 FAN CONTROL CIRCUIT BYPASS TEST 10 16 COOLANT TEMPERATURE SENSOR 10 16 FAN MOTOR CURRENT DRAW 10 17 GEAR POSITION INDICATOR SWITCH 10 17 TEST DIAGRAM 10 17 ELECTRONIC THROTTLE CONTROL ETC SWITCH 10 18 ETC SWITCH OPERATION 10 18 ETC OPERATION TEST 10 18 IGNITION SY...

Page 322: ...0 38 STARTER MOTOR REMOVAL DISASSEMBLY 10 38 BRUSH INSPECTION REPLACEMENT 10 39 ARMATURE TESTING 10 40 STARTER REASSEMBLY INSTALLATION 10 41 STARTER SOLENOID BENCH TEST 10 41 STARTER DRIVE 10 42 STARTER EXPLODED VIEW 10 43 STARTER SYSTEM TESTING FLOW CHART 10 44 BASIC WINCH WIRING PRE WIRED MODELS 10 45 BATTERY 10 46 BATTERY IDENTIFICATION 10 46 BATTERY ACTIVATION CONVENTIONAL 10 46 BATTERY TERMIN...

Page 323: ...rmal 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 the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays wit...

Page 324: ...ion if the voltage on the DC bus is excessive This is usually the result of an open battery condition and the gauge is designed to survive such an event NOTE If the gauge will not indicate what gear it is in and will not allow AWD operation AWD can still be enabled by holding in the mode override button 1 Turn the key switch off and wait 10 seconds 2 Set the park brake and shift the transmission t...

Page 325: ... current is flowing through the AWD coil on models with AWD Screen 4 Gear Circuit Diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge NOTE 10 20 Variance from these reading is within normal parameters Ill 3 AWD Off AWD On 23 Ohms in Park 158 Ohms in Neutral 75 Ohms in Reverse ...

Page 326: ...g When the 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 OFF 1 If the service interval is enabled functioning on your ATV and you wish to turn it off toggle to the service interval mode 2 Press and hold the mode button for approximately 7 seconds u...

Page 327: ...I Diagnostic Mode NOTE The EFI diagnostic mode is intended to quickly view fault codes stored in the EFI module Polaris dealers are equipped with the proper diagnostic tools to further diagnose the blink code To download blink codes failure codes from you EFI module 1 Be sure the ATV key switch is off and with the shifter is in Park 2 Turn the key switch ON and OFF 3 times within 5 seconds leaving...

Page 328: ...it Short to Ground 42 Engine Temp Sensor Circuit Open or Short to Battery 51 Injector 1 Open Load 51 Injector 1 Short Circuit to Ground 51 Injector 1 Short Circuit to Battery 52 Injector 2 Open Load 52 Injector 2 Short Circuit to Ground 52 Injector 2 Short Circuit to Battery 54 Engine Temp Lamp Open Load 54 Engine Temp Lamp Short Circuit to Ground 54 Engine Temp Lamp Short Circuit to Battery 55 Di...

Page 329: ...nstalled and that the indexing key is in the headlight pod keyway 3 Hold the pod assembly securely and insert the instrument cluster into the pod assembly Twist the instrument cluster gently in a clockwise motion to properly seat the instrument cluster into the pod assembly Apply pressure on the bezel while pressing down on the instrument cluster NOTE Do not allow alcohol or petroleum products to ...

Page 330: ...10 10 ELECTRICAL SPEEDOMETER TROUBLESHOOTING Test 1 No All Wheel Drive ...

Page 331: ...10 11 ELECTRICAL 10 TEST 2 No Display TEST 3 No Reverse Speed Limit ...

Page 332: ...10 12 ELECTRICAL TEST 4 No AWD Hub Safety Limiter ...

Page 333: ...10 13 ELECTRICAL 10 TEST 5 Reverse Speed Limiter TEST 6 Speed Sensor ...

Page 334: ...10 14 ELECTRICAL TEST 7 No Fuel Gauge TEST 8 Transmission Switch ...

Page 335: ...ORTANT 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 by bad failed connections and grounds NOTE Refer to the ADC subsystem diagram located in Wire Diagrams at the end of this chapter ALL WHEEL DRIVE AWD COIL Operation Overview AWD switch must be ON 12Vdc power is presen...

Page 336: ...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 temperature sensor and connector terminals Coolant Temperature Sensor The coolant temperature sensor can be tested using an ohmmeter or voltmeter 1 With the engine and temperature sensor at room temperature 68 F 20 ...

Page 337: ...h to ON position Read the current draw on ammeter with fan running 5 If the fan motor draws more than 15 Amps replace the motor NOTE This fan motor current draw specification only applies to Sportsman EFI models GEAR POSITION INDICATOR SWITCH Test Diagram Fan Motor Current Draw Should Be Less Than 15 Amps Connect Ammeter Between Org Black Pins Org Blk Fan Motor Brn Org Blk Fan Harness NOTE Also se...

Page 338: ...or engine stop switch OFF NOTE Test the ETC switch at the harness connector ETC will not activate unless there is throttle plate movement off of zero detected by the ECU Adjust throttle cable freeplay ETC switch and make sure throttle mechanism is functioning properly before testing the switch Refer to Maintenance Chapter 2 for cable adjustment procedure ETC Operation Test 1 Remove throttle block ...

Page 339: ...itial ignition charge An A C signal from the Crank Shaft Position Sensor is processed by the ECU which determines ignition timing by calculating from a point pre determined in the crankshaft rotation This signal releases the electrical charge which saturates the coil for ignition DC CDI systems have the ability to ignite with as little as 6 volts of power Some of the advantages of DC ignition are ...

Page 340: ...ttery to Solenoid Cable Ignition Coils Solenoid Switch starter Coil Wires Control Module Fuses Spark Plugs Voltage Regulator Crank Position Sensor Flywheel Stator Assembly Pre Wire Winch Cables Negative Battery Cable Relays Starter Solenoid Cable 30 Amp hr Battery ...

Page 341: ...ing in connectors etc Faulty ignition coil winding measure resistance of primary and secondary Sheared flywheel key Flywheel loose or damaged Faulty ECU CHARGING SYSTEM Current Draw Key Off Connect an ammeter in series with the negative battery cable Check for current draw with the key off If the draw is excessive loads should be disconnected from the system one by one until the draw is eliminated...

Page 342: ...oximately 1500 RPM or lower 8 With the engine running turn the lights on and engage parking brake lock to keep brake light on 9 Repeat test observing ammeter and tachometer With lights on charging should occur at or below 2000 RPM Alternator Output Test Three tests can be performed using a multimeter to determine the condition of the stator alternator TEST 1 Resistance Value of Each Stator Leg 1 M...

Page 343: ...ATV at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 4 Refer to the table below for approximate Voltage AC readings according to RPM Test each leg at the specified RPM in the table Example The alternator voltage output reading should be approximately 18 Vac at 1300 RPM b...

Page 344: ...tting AC Amps Reconnect the alternator wires Note Red wire must be connected to harness Battery voltage must be present on red wire terminal on harness side of voltage regulator connector Is it Meter Setting DC Volts If all of the previous tests indicate a good condition but the charging voltage does not rise above battery voltage at the connector or wire harness replace the voltage regulator Yes ...

Page 345: ... relay to turn on the fan Red White KEY ON Battery power supply switched on by the key and LH control switches enables power to relay Orange Black KEY ON Battery power supply switched on by the key and LH control switches enables power to relay POWER RELAY COLOR FUNCTION Red White KEY ON Battery power supply switched on by the key and LH control switches enables power to relay Tied to Fan Relay te...

Page 346: ... Power and Accessories A 20 amp circuit breaker protects the fan circuit LIGHTING High Beam Headlight Bulb Replacement 1 Remove three Phillips screws on the headlight pod 2 Lift pod cover up 3 Disconnect instrument cluster harness A and work light switch B CAUTION Do not service while headlight is hot Serious burns may result Protect lamp during install Remove 3 Screws A B ...

Page 347: ... and harness assembly into the headlight assembly Turn the headlight harness clockwise to secure the headlamp into place Headlight Housing Replacement 1 Remove three Phillips screws on the headlight pod 2 Disconnect instrument cluster harness A and work light switch B 3 Unplug headlamp harness C 4 Remove O Ring D from headlight pivot pins Both Sides 5 Pull the headlight housing up to release from ...

Page 348: ...th 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 headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be include...

Page 349: ...emoval if required 5 Remove the screw that secures the lower headlamp 6 Pull the headlamp out of the locking tab Low Beam Headlight Adjustment 1 The low beam can be adjusted slightly upward or downward 2 Loosen the phillips screw located at the rear of the headlamp 3 Tilt the headlamp upward or downward 4 Tighten the screw Headlamp Switch Test 1 Remove the headlight pod cover 2 Set meter to DC Vol...

Page 350: ...tch in ON position Probe the worklight plug wires at back of vehicle there should be at least 12Vdc at the plug Check for 12 Vdc at the blue wire Sportsman Brake Light Work Light Deluxe Replacement The brake light A and the work light B are both located in the rear tail lamp housing 1 To remove the worklight electrical connector B pull down on the connector lock and pull the connector from the bul...

Page 351: ...parts manual for the correct bulb part number X2 BRAKE LIGHT WORK LIGHT Deluxe REPLACEMENT The brake light A and the work light B are both located in the rear tail lamp housing 1 Open the tailgate and remove the 2 torx head screws A securing the rear taillights on each side of the cargo box as illustrated below 2 Remove the taillight assembly from the cargo box A CAUTION Use caution when disconnec...

Page 352: ... to remove from lamp assembly Brake Light Switch 1 Remove the front cover 2 Disconnect wire harness from switch 3 Connect an ohmmeter across switch contacts Reading should be infinite 4 Apply brake at handlebar lever and check for continuity between switch contacts Replace switch if there is no continuity or greater than 5 ohms resistance when the brake is applied with slight pressure Black Tab Re...

Page 353: ...at Float contact with tank Bent Float Rod If none of the conditions exists the sender assembly is faulty Fuel pump assembly replacement is required X2 DIFFERENTIAL SYSTEM Solenoid Testing Disconnect from the wire harness Using a digital ohmmeter test the solenoid at the connector leads and compare to the specification Replacement of solenoid is required as it is not serviceable Solenoid Replacemen...

Page 354: ...RF switch for proper function IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting an ECU failure 80 of all electrical issues are caused by bad failed connections and grounds X2 SPEED SENSOR Testing Using the special tools listed test the speed sensor according to the tester instructions Remove sensor and inspect the o ring ...

Page 355: ...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 right side If you have trouble locating the Orange White wires remove the left side panel and search under the front fender area NOTE Refer to the accessory instructions for accessory hook up and install...

Page 356: ...on switch runs to the wire harness splice The ECU will allow starting in Neutral or Park without the brake applied Applying the brake overrides this system and allows starting regardless of transmission shift position Items to check when diagnosing a no start condition are Transmission switch for proper function Starter solenoid for proper function Brake switch for proper function Wire harness loo...

Page 357: ... runs to the wire harness splice The ECU will allow starting in Neutral or Park without the brake applied Applying the brake overrides this system and allows starting regardless of transmission shift position Items to check when diagnosing a no start condition are Transmission switch for proper function Starter solenoid for proper function Brake switch for proper function Wire harness loose connec...

Page 358: ...ter motor gear Faulty flywheel gear or loose flywheel Voltage Drop Test The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC per connection or component To perf...

Page 359: ...insulated 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 360: ...ommutator segment and the armature shaft The reading 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 ...

Page 361: ...329 lubricate brush end bushing 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...

Page 362: ...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 363: ... 3 Thrust Washer 4 Gear Assembly 5 O Ring 6 Brush Complete 7 O Ring 8 Thrust Washer 9 Shaft Complete 10 Gear Assembly 11 Through Bolt 12 Cover 13 Stopper 14 Snap Ring 15 Washer 16 Flange Bolt 17 Thrust Washer 18 Flange Bushing Indicates Do not reuse Replace with new parts ...

Page 364: ... Test starter solenoid coil by connecting an ohmmeter between the solenoid wire and the solenoid mounting plate Resistance should be 3 4 Ω Check solenoid ground path by measuring resistance between mounting plate and battery negative terminal 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 sta...

Page 365: ...10 45 ELECTRICAL 10 BASIC WINCH WIRING PRE WIRED MODELS ...

Page 366: ...Remove 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 Caps Top View Electrolyte Level Indicator No Caps Non Removable Top View No Electrolyte Level Indicator Sealed Low Maintenance Battery Conventional Battery WARNING Battery electrolyte is poisonou...

Page 367: ...e lower 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 followed by the positive red cable 3 Remove the battery 4 Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery NOTE Re...

Page 368: ...rolyte strength or specific gravity As the battery goes through the charge discharge cycle the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged The hydrometer can measure state of charge and differences between cells in a multi cell battery Readings of 1 270 or greater should be observed in a fully charged battery Differences of more than 0...

Page 369: ... or knife remove any corrosion from the cables and terminals Make sure that the electrolyte is at the proper level Add distilled water if necessary Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Recharge to full...

Page 370: ... New 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 hour capacity Do not use the alternator to charge a new battery Refer to Battery Activation and Maintenance video PN 9917987 NEVER attempt to add electrolyte or water to a Low Maintenance battery...

Page 371: ...e well with clean water and dry thoroughly 2 Route the cables correctly 3 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt threads with Nyogel Grease PN 2871329 4 Reinstall the holder strap BATTERY CHARGING REFERENCE TABLE STATE OF CHARGE VOLTAGE ACTION CHARGE TIME 100 12 8 13 V None check voltage at 3 mos after manufacture date None Re...

Page 372: ...harge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perform this test 1 Hook a multitester to the battery in the same manner as was done in the OCV test The reading shoul...

Page 373: ... a non use period If the battery is stored during the winter months electrolyte will freeze at higher temperatures as the battery discharges The chart below indicates freezing points by specific gravity Low Maintenance 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 variable rate charging output...

Page 374: ...NOTES ELECTRICAL 10 54 ...

Page 375: ...D LOCK ASSEMBLY 11 4 STEERING ASSEMBLY EXPLODED VIEW 11 4 800 EFI INTERNATIONAL ELECTRICAL 11 5 TURN HAZARD SIGNAL DIAGRAM 11 5 NOTE This chapter illustrates components that are unique to the Sportsman 800 EFI International Except where noted any servicing of these components or other components on the ATV can be done using this service manual s procedures and illustrations ...

Page 376: ...ll 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 calipers while the other line exits the proportioning valve and feeds the outer line to the rear calipers When the hand brake is applied all brake calipers are active as braking pressure is routed from the hand brake mas...

Page 377: ...11 3 800 EFI INTERNATIONAL 11 Exploded View Foot Brake Supply Hand Brake Supply ...

Page 378: ...ded View The 800 EFI International Sportsman is equipped with a locking mechanism to prevent theft or unauthorized use Steering post removal may be required for lock service or repair Lock System Item Number Description 11 Lock Collar 12 Lock Set 13 Bolt Lock Set 14 Bolt s Lock Collar 15 Nut s Lock Collar ...

Page 379: ...11 5 800 EFI INTERNATIONAL 11 800 EFI INTERNATIONAL ELECTRICAL Turn Hazard Signal Diagram ...

Page 380: ...NOTES 800 EFI INTERNATIONAL 11 6 ...

Page 381: ...7 Brake Pad Removal and Installation 9 10 Brake System Components Std Sportsman 9 4 Brake System Components X2 9 3 Brake System Exploded View International 11 3 Brake System Exploded Views 9 3 Brake System Inspection 2 26 Brake System Overview International 11 2 Brake Master Cylinder Removal 9 9 Brake Rear Auxiliary Brake 9 28 Brake Rear Auxiliary Master Cylinder 9 26 Brake Torque Specifications 9...

Page 382: ...Piston Installation 3 45 Engine Piston Removal Inspection 3 30 Engine Piston Ring Installed Gap 3 33 Engine Piston to Cylinder Clearance 3 32 Engine Piston to Rod Clearance 3 32 Engine Pushrod Inspection 3 22 Engine Removal Install Procedure 3 16 Engine Rocker Arm Inspection 3 22 Engine Service Specifications 3 11 Engine Starter Drive Removal 3 33 Engine Starter Removal 3 35 Engine Stator Gear Cov...

Page 383: ...Identification Chart 2 10 Lubrication Grease Points 2 11 M Maintenance Chart Periodic 2 3 Maintenance Schedule 2 36 Misc Tables 1 12 Model 1 2 Model Number VIN Identification 1 2 O Oil Pump Disassembly 3 39 Oil Pump Reassembly 3 40 Oil Pump Removal 3 39 P Paint Codes 1 3 Passenger Seat Operation 5 29 Piston Ring Installed Gap 3 33 Piston to Cylinder Clearance 3 32 Piston to Rod Inspection 3 32 Pla...

Page 384: ...fication Wheel Toe Out 2 25 Specifications Body and Steering Torque Values 5 2 Specifications Brake Component Service Limits 9 2 Specifications Brake Component Torque Values 9 2 Specifications Cam Shaft 3 43 Specifications Cooling System 3 14 Specifications Crankcase Fastener Torque 3 44 Specifications Engine Lubrication 3 20 Specifications Engine Oil Pressure 3 20 Specifications Final Drive Torqu...

Page 385: ...Reassembly 8 32 Transmission Removal 8 23 Transmission Special Tools 8 23 Troubleshooting EFI Circuit Diagrams 4 21 U U joint Disassembly and Assembly 7 7 V Valve Seal Spring Service 3 23 Valve Sealing Test 3 29 Valve Seat Reconditioning 3 26 Vent Lines 2 16 Voltage Drop Test 10 38 W Warn Winch Operation 2 31 Wheel Alignment 2 25 Wheel Installation 2 29 Wheel Removal 2 29 Winch Basic Wiring Diagra...

Page 386: ...IX 6 ...

Page 387: ...WD 1 WIRE DIAGRAM 2007 SPORTSMAN ACTIVE DESCENT CONTROL ADC WIRE DIAGRAM ...

Page 388: ...WD 3 WIRE DIAGRAM 2007 SPORTSMAN 700 800 EFI WIRE DIAGRAM ...

Page 389: ...WD 4 WIRE DIAGRAM ...

Page 390: ...WD 5 WIRE DIAGRAM 2007 SPORTSMAN 800 X2 EFI WIRE DIAGRAM ...

Page 391: ...WD 6 WIRE DIAGRAM ...

Page 392: ...WD 7 WIRE DIAGRAM 2007 SPORTSMAN 800 EFI INTERNATIONAL WIRE DIAGRAM ...

Page 393: ...WD 8 WIRE DIAGRAM ...

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