Polaris 2012 Sportsman Forest 500 International Service Manual Download Page 340

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9.10

BRAKES

9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual

BRAKE CALIPER EXPLODED VIEWS

Sportsman 400 HO, 500 HO, Touring and Forest 500 (INTL.) Front Caliper Assembly

Sportsman 500 HO Touring Rear Caliper Assembly (non INTL.)

A. Socket Set Screw
B. Bleeder Screw



C. Caliper Asm.



D. Boot



E. Square O-rings



F. Piston



G. Caliper Mount



H. Brake PAds

Disc brake caliper
lube

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

Apply Polaris DOT-approved
Brake Fluid to Component

Disc brake caliper
lube

Summary of Contents for 2012 Sportsman Forest 500 International

Page 1: ...1 GENERAL 2 MAINTENANCE 3 ENGINE 4 FUEL SYSTEMS 5 BODY SUSPENSION...

Page 2: ...6 CLUTCH 7 FINAL DRIVE 8 TRANSMISSION 9 BRAKES 10 ELECTRICAL...

Page 3: ...NOTES...

Page 4: ...UMBERS 1 2 TRANSMISSION I D LOCATION 1 3 PUBLICATION PART NUMBERS 1 3 VEHICLE SPECIFICATIONS 1 4 2012 SPORTSMAN 400 H O 1 4 2012 SPORTSMAN 500 H O 1 6 2012 SPORTSMAN TOURING 500 HO 1 8 2012 SPORTSMAN...

Page 5: ...mber are important for vehicle identification Be sure to refer to the engine model number and serial number A whenever corresponding about an engine This information can be found on the sticker applie...

Page 6: ...50AX AZ 9923410 9923411 2012 Sportsman Touring 500 H O International A12DH50FX 9923438 9923413 2012 Sportsman 400 H O A12MH46AX AZ 9923420 9923421 2012 Sportsman 500 H O A12MH50AD AQ AX AZ 9923420 992...

Page 7: ...on Pressure 50 90 psi Engine Idle Speed 1200 200 RPM Engine Max Speed 7000 RPM Cooling System Cap Liquid 2 7 qt 2 5 L Overheat Warning HOT on Instrument Cluster Lubrication Dry Sump Oil Requirements P...

Page 8: ...RS Progressive Rate Rear Travel 9 5 24 1 cm Turning Radius 65 in 165 1 cm unloaded Shock Preload Adjustment Front Rear Front Non Adjustable Rear Ratchet Style Std Toe Out 0 1 16 in 0 159 mm Wheels Bra...

Page 9: ...oke mm 92 x 75 mm Compression Ratio 10 2 1 Compression Pressure 70 90 psi W Compression Release Engine Idle Speed 1200 200 RPM Engine Max Operating Rpm 7000 Rpm 200 Rpm Cooling System Capacity Liquid...

Page 10: ...3 cm Ground Clearance 11 25 in 28 6 cm Shock Preload Adjustment Front Rear Front Non Adjustable Rear Ratchet Style Std Turning Radius 65 in 165 10 cm unloaded Toe Out 0 1 16 in 0 159 mm Wheels Brakes...

Page 11: ...m Compression Ratio 10 2 1 Compression Pressure 70 90 psi W Compression Release Engine Idle Speed 1200 200 RPM Engine Max Operating Rpm 7000 RPM Cooling System Capacity Liquid 2 7 qt 2 5 ltr Overheat...

Page 12: ...13 cm Ground Clearance 11 25 in 28 6 cm Shock Preload Adjustment Front Rear Front Non Adjustable Rear Ratchet Style Std Turning Radius 65 in 165 10 cm unloaded Toe Out 0 1 16 in 0 159 mm Wheels Brakes...

Page 13: ...bs 82 kg ENGINE Platform Fuji 4 stroke Single Cylin der Engine Model Number EH500PLE216 Engine Displacement 498cc Number of Cylinders 1 Bore Stroke mm 92 x 75 mm Compression Ratio 10 2 1 Compression P...

Page 14: ...T EBS Belt 3211113 Steering Suspension Front Suspension Shock A arm MacPherson Strut Front Travel 8 2 in 20 8 cm Rear Suspension Shock Progressive Rate Indepen dent w 2 Coil over shock Rear Travel 9 5...

Page 15: ...ams g x 0 035 Ounces oz lb x 454 kg kg x 2 2046 lb Cubic inches 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...

Page 16: ...2 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 Bolt Size Grade 4 6 4 8 8 8 8 9 10 9 12 9 Ft Lbs Nm Dry Threads...

Page 17: ...23 mm 9055 29 32 9063 59 64 9219 15 16 9375 24 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...

Page 18: ...key is take the first two digits on the original key and refer to the chart to the right for the proper part number Should both keys become lost ignition switch replacement is required PAINTED PART C...

Page 19: ...of one kilogram at the end of a lever one meter in length applied in a rotational direction l or ltr Liter Left Side Always referred to based on normal operating position of the driver m Meter meters...

Page 20: ...JUSTMENT 2 13 FUEL SYSTEM 2 13 FUEL LINES 2 14 VENT LINES 2 14 CHOKE ENRICHER ADJUSTMENT 500 CARB 2 14 COMPRESSION TEST 2 14 ENGINE MOUNTS 2 14 SPARK PLUG 2 15 BATTERY MAINTENANCE 2 15 LIQUID COOLING...

Page 21: ...OLS 2 30 WHEELS 2 30 WHEEL HUB AND SPINDLE TORQUE TABLE2 30 WHEEL REMOVAL FRONT OR REAR 2 31 WHEEL INSTALLATION 2 31 TIRE PRESSURE 2 31 TIRE INSPECTION 2 32 FRAME NUTS BOLTS FASTENERS 2 32 CARBURETOR...

Page 22: ...oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance C...

Page 23: ...e ADC fluid level if equipped Pre Ride Brake fluid level Pre Ride Brake lever travel Pre Ride Brake systems Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride E Engine oil level Pre Ride Pass...

Page 24: ...grease fittings pivots cables etc Shift Linkage 50 H 6 M 310 500 Inspect lubricate adjust Steering 50 H 6 M 310 500 Lubricate Front suspension 50 H 6 M 310 500 Lubricate Rear suspension 50 H 6 M 310...

Page 25: ...1000 Inspect clean external surfaces Cooling hoses 100 H 12M 620 1000 Inspect for leaks Engine mounts 100 H 12M 620 1000 Inspect Exhaust muffler pipe 100 H 12M 620 1000 Inspect E Spark plug 100 H 12M...

Page 26: ...vehicle for any damaged or loose nuts bolts or fasteners Engine coolant check for proper level at the recovery bottle Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS...

Page 27: ...tion C Grease conforming to NLGI No 2 such as Polaris Premium All Season Grease Conoco Superlube M or Mobilgrease Special ITEM LUBE METHOD FREQUENCY 1 Engine Oil Polaris PS 4 Plus Check oil tank dipst...

Page 28: ...nt of lubricant or be filled to the bottom of the fill plug hole threads Refer to procedures To Change Gearcase Lubricant 1 Remove gearcase drain plug A located on the bottom of the gearcase and drain...

Page 29: ...correct when it reaches the bottom of the fill hole threads NOTE The check fill plug is a 5 16 hex To Change Lubricant 1 Remove transmission drain plug to drain the oil Discard used oil properly NOTE...

Page 30: ...tered with inadequate bleed of the hydraulic circuit 5 Begin the bleeding process by filling reservoir to MAX line with clean Polaris Demand Drive PLUS hydraulic fluid 6 Locate bleeder valves found on...

Page 31: ...d let it idle 4 Turn handlebars from full right to full left If idle speed increases at any point in the turning range inspect throttle cable routing and condition Adjust cable tension as needed until...

Page 32: ...it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short tim...

Page 33: ...essor Compression readings will vary in proportion to cranking speed during the test Average compression measured is about 60 90 psi during a compression test Smooth idle generally indicates good comp...

Page 34: ...battery condition and charge accordingly New Batteries Batteries must be fully charged before use or battery life can be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current e...

Page 35: ...period Overheating of engine could occur if air is not fully purged from system Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water Coolant Strength Type Test the stren...

Page 36: ...move radiator cap and test using a cap tester commercially available 2 The radiator cap relief pressure is 13 lbs 89 6 kpa RECOMMENDED COOLANT Use only high quality antifreeze coolant mixed with disti...

Page 37: ...properly To Access the Radiator Pressure Cap 1 Open the front rack storage area 2 Remove the 4 T 25 screws securing the access cover to the front cab as shown below 3 Move the seal out of the sealing...

Page 38: ...aning 5 Slip the pre filter element off of main element Clean the pre filter with hot soapy water 6 Rinse and dry thoroughly 7 Inspect element for tears or damage 8 Inspect main filter and replace if...

Page 39: ...d when the foam air box pre filter is in place and maintained properly Never operate the engine without the pre filter Recoil Housing Drain the housing periodically to remove moisture If Equipped Drai...

Page 40: ...el is over the full mark change the oil Oil and Filter Change NOTICE Care must be taken to ensure that the fluids are contained Be prepared to collect the fluid with suitable containers before opening...

Page 41: ...il filter Use Oil Filter Wrench PV 43527 turn filter counterclockwise to remove 16 Using a clean dry cloth clean filter sealing surface on the crankcase 17 Lubricate the o ring on new filter with a th...

Page 42: ...earance while the engine is cold and the piston positioned at Top Dead Center TDC on compression stroke 1 Remove the seat 2 Remove body panels and fuel tank as necessary to gain access to valve cover...

Page 43: ...utch Adjuster Tool PA 44689 can be used to adjust the engines valves NOTE Both feeler gauges should remain inserted during adjustment of each valve 3 When clearance is correct hold adjuster screws and...

Page 44: ...bars in a straight ahead position and secure handlebars in this position NOTE The steering arm center section can be used as an indicator of whether the handlebars are straight The center section shou...

Page 45: ...m of the muffler 2 Place the transmission in Park and start the engine Purge accumulated carbon from the system by momentarily revving the engine several times CAUTION During tie rod adjustment it is...

Page 46: ...Set the hand brake and block the wheels Make sure the machine is in Park and repeat Steps 2 and 3 SEE WARNING 6 Repeat steps 2 through 5 until no more particles are expelled when the engine is revved...

Page 47: ...en any loose fittings and replace any worn or damaged parts Auxiliary Brake Testing The auxiliary brake should be checked for proper function 1 Support the rear wheels off the ground 2 While turning t...

Page 48: ...Bleed the hydraulic auxiliary brake system in a conventional manner following the procedure outlined in Brake Chapter 9 Suspension Spring Preload Adjustment Operator weight and vehicle loading affect...

Page 49: ...wheels for runout or damage Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts Wheel Hub And Spindle Torque Table Throttle assembly clamp Align clamp edge with knurl WARNIN...

Page 50: ...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...

Page 51: ...er the rubber boot between the choke knob and nut Firmly grasp the rubber boot and tighten until the choke slides freely but stays out when pulled Pilot Screw The pilot system supplies fuel during eng...

Page 52: ...or seat will be permanently damaged 3 Connect an accurate tachometer that will read in increments of or 50 RPM such as the PET 2100DX PN 8712100DX or the PET 2500 PN 8712500 Pilot Screw Location Brass...

Page 53: ...clockwise to increase or out counterclockwise to decrease RPM Refer to Ill at right NOTE Adjusting the idle speed affects throttle cable freeplay and electronic throttle control ETC adjustment Always...

Page 54: ...de of the float bowl 1 Turn fuel valve to the OFF position 2 Place a clean container beneath the bowl drain spigot or bowl drain hose 3 Turn drain screw out two turns and allow fuel in the float bowl...

Page 55: ...2 36 MAINTENANCE Copyright 2011 Polaris Sales Inc 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Maintenance Schedule Service Date Hours Miles Service Performed Serviced By...

Page 56: ...S 3 17 ENGINE DISASSEMBLY 3 18 CAM CHAIN TENSIONER ROCKER ARM CAMSHAFT REMOVAL 3 18 CAM CHAIN TENSIONER INSPECTION 3 18 ROCKER ARM SHAFT INSPECTION 3 19 CAMSHAFT REMOVAL 3 20 AUTOMATIC COMPRESSION REL...

Page 57: ...END PLAY ADJUSTMENT 3 45 ENGINE REASSEMBLY 3 45 PUMP SHAFT OIL SEAL INSTALLATION 3 45 CRANKSHAFT COUNTER BALANCE OIL PUMP INSTALLATION 3 45 CRANKCASE ASSEMBLY 3 46 WATER PUMP MECHANICAL SEAL INSTALLA...

Page 58: ...m 45 49 61 67 Nm 6 8 9 11 Nm Cylinder Head Bolts 11mm 6mm Refer to Engine Assembly for torque procedure Drive Clutch Bolt 7 16 20 40 55 Nm Flywheel 16mm 58 72 78 98 Nm Oil Delivery Pipe 12mm 11 15 15...

Page 59: ...mshaft journal bore ID Mag 1 4963 1 4970 38 005 38 025 mm PTO 1 4963 1 4970 38 005 38 025 mm Camshaft Oil clearance Std 0022 0035 055 090 mm Limit 0039 10 mm Cylinder Head Surface warpage limit 0020 0...

Page 60: ...rd inner diameter of piston pin bore 9055 9057 23 0 23 006 mm Piston Pin Outer diameter 9053 9055 22 994 23 0 mm Standard clearance piston pin to pin bore 0002 0003 004 008 mm Degree of fit Piston Pin...

Page 61: ...38 005 38 025 mm Camshaft Oil clearance Std 0022 0035 055 090 mm Limit 0039 10 mm Cylinder Head Surface warpage limit 0020 05 mm Standard height 3 855 97 92 mm Valve Seat Contacting width In Std 028 7...

Page 62: ...r diameter of piston pin bore 9055 9057 23 0 23 006 mm Piston Pin Outer diameter 9053 9055 22 994 23 0 mm Standard clearance piston pin to pin bore 0002 0003 004 008 mm Degree of fit Piston Pin must b...

Page 63: ...5 Water Pump Install Kit 2870569 Crankshaft Truing Stand 2870975 Mity Vac Pressure Test Tool PV 43527 Oil Filter Wrench Condition Approx Reading Min Max Temperature Temperature 37 3 39 2 k 68 F 20 C S...

Page 64: ...diator all cooling system hoses and clamps or water pump seal Radiator Cap Pressure Test 1 Remove radiator cap and test using a cap tester commercially available 2 The radiator cap relief pressure is...

Page 65: ...Refer to Accessible Components for further information NOTE Upon engine removal use a mechanical lift or have an assistant help remove the engine from the vehicle to prevent personal injury or damage...

Page 66: ...the engine intake boots Remove the throttle body and support it out of the way Do not allow the throttle body to hang from the throttle cable 500 EFI 17 Insert a shop towel into the intake manifold to...

Page 67: ...ng of the radiator 2 Fill coolant reservoir tank to full mark 3 Install radiator cap and squeeze coolant lines to force air out of system 4 Again remove radiator cap and slowly add coolant to top of f...

Page 68: ...rp edges or burrs paying particular attention to the corners of the intake and exhaust ports Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honin...

Page 69: ...on at right When rebuilding and straightening a crankshaft runout must be as close to zero as possible NOTE Maximum allowable runout is 0024 Engine Lubrication Oil Type Polaris Premium 4 Synthetic or...

Page 70: ...he crankshaft An oil seal on the stator plate prevents oil from entering the stator flywheel area Oil travels through the crankshaft to the crank pin lubricating the connecting rod large end bearing d...

Page 71: ...Valve Bypass Oil Filter Delivery Pipe Crankshaft Prevents oil from draining into crankcase with engine off Top of Oil Tank Delivery Pipe Delivery Pipe Crank Pin Large End Bearing Cylinder Sleeve Small...

Page 72: ...3 17 ENGINE 3 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Engine Exploded Views Crankshaft Cylinder and Piston Cylinder Head Crankcase Valvetrain...

Page 73: ...gned with the camshaft to crankshaft center line NOTE The cam lobe should be pointing down and valves should have clearance at this point 5 Remove cam chain tensioner plug sealing washer and spring CA...

Page 74: ...ly 2 Inspect each rocker arm cam follower surface If there is any damage or uneven wear replace the rocker arm NOTE Always inspect camshaft lobe if rocker arms are worn or damaged 3 Measure O D of roc...

Page 75: ...sing 2 Remove camshaft sprocket inspection cover 3 Loosen three camshaft sprocket bolts 4 Remove camshaft end cap and O ring 5 Inspect camshaft end cap thrust face for wear Replace if worn or damaged...

Page 76: ...utomatic Compression Release Installation 1 Slide spring onto shaft 2 Apply engine oil to release lever shaft The actuator ball must be held outward to allow installation of the release lever shaft If...

Page 77: ...if camshaft journal bore is damaged or worn excessively Cylinder Head Removal 1 Remove the two 6mm flange bolts A from cylinder head See exploded view on next page 2 Loosen each of the four cylinder h...

Page 79: ...s the service limit replace the cylinder head Cylinder Head Disassembly NOTE Keep all parts in order with respect to their location in the cylinder head 1 Using a valve spring compressor C compress th...

Page 80: ...ing pitting wear or damage A 4 Inspect split keeper groove for wear or flaring of the keeper seat area B NOTE The valves cannot be re faced or end ground They must be replaced if worn bent or damaged...

Page 81: ...se a torch to heat cylinder head or warpage may result from uneven heating Head temperature can be checked with a pyrometer or a welding temperature stick Follow the manufacturer s instructions provid...

Page 82: ...on the pilot and make a light cut 13 Inspect the cut area of the seat If the contact area is less than 75 of the circumference of the seat rotate the pilot 180o and make another light cut If the cutt...

Page 83: ...a all the way around the valve face 17 Clean all filings from the area with hot soapy water rinse and dry with compressed air 18 Lubricate the valve guides with clean engine oil and apply oil or water...

Page 84: ...ap lightly with soft faced hammer on the end of the valves to seat the split keepers Valve Sealing Test 1 Clean and dry the combustion chamber area 2 Pour a small amount of clean high flash point solv...

Page 85: ...four oil pipe banjo bolts and then remove the bolts and eight sealing washers Remove the pipes 3 Loosen hose clamps and remove coolant inlet hose 4 Remove the two 6 mm cylinder base bolts 5 Loosen eac...

Page 86: ...g 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 P...

Page 87: ...bored oversize or replaced Cylinder Hone Selection Honing Procedure Cylinders may be wet or dry honed depending upon the hone manufacturer s recommendations Wet honing removes more material faster and...

Page 88: ...burrs paying particular attention to the corners of the intake and exhaust ports Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove...

Page 89: ...Step 5 above Piston Rod Inspection 1 Measure piston pin bore 2 Measure piston pin O D Replace piston and or piston pin if out of tolerance 3 Measure connecting rod small end ID Piston to Cylinder Clea...

Page 90: ...equal 25mm 010 over sized Pistons and rings marked 50 equal 50mm 020 oversized Piston Ring Installed Gap 1 Place each piston ring inside cylinder using piston to push ring squarely into place as shown...

Page 91: ...sure in two directions 90o apart to determine if bushing is out of round Calculate bushing clearance Replace bushing if clearance exceeds the service limit 6 Inspect gear teeth on starter drive Replac...

Page 92: ...Inspect chain for worn or missing rollers or damage Stretch chain tight on a flat surface and apply a 10 lb 4 53 kg load Measure length of a 20 pitch section of chain Replace if worn past service lim...

Page 93: ...case by tapping with a soft faced hammer in reinforced areas 3 Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary to ensure the balancer shaft stays in the...

Page 94: ...thoroughly 8 Remove pump body screw and feed chamber cover 9 Measure pump end clearance using a feeler gauge and straight edge 10 Measure rotor tip clearance with a feeler gauge 11 Remove inner and o...

Page 95: ...im washer A from the counter balancer shaft 2 Note the alignment dots on the balancer and crankshaft gears the marks must be aligned during reassembly 3 Turn the shaft until balancer counter weights c...

Page 96: ...rface or connecting rod 3 Use a feeler gauge to measure the connecting rod big end side clearance 4 Place the crankshaft in a truing stand or V blocks and measure the runout on both ends with a dial i...

Page 97: ...nd hole bearing puller NOTE Bearings are stressed during the removal process and should not be re used Oil Seal Mechanical Seal Removal Engine Disassembled NOTE The water pump mechanical seal can be r...

Page 98: ...0 for pump shaft bearing End Play Inspection Adjustment Before reassembling the crankcase the following steps should be performed to determine the amount of crankshaft counter balancer shaft and pump...

Page 99: ..._______________ 8 Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6 and record below Total End Play______________________ 9 Subtract the thickness of the ex...

Page 100: ...result of Step 3 to determine if a different shim is needed See Pump Shaft End Play specification below ENGINE REASSEMBLY Pump Shaft Oil Seal Installation 1 Install the seal from the outside of the cr...

Page 101: ...are in place 2 Set the crankcase in position carefully to avoid damaging the pump shaft seal and install the magneto end crankshaft installation tool follow instructions provided with the Crankshaft...

Page 102: ...f the tool 5 Tighten the hex socket screws on the puller legs sufficiently so the lip of the puller legs will grasp the mechanical seal 6 Turn the puller T Handle clockwise until it contacts the water...

Page 103: ...ck piston ring installed gap before rings are installed on piston see Page 3 29 If the piston has been in service clean any accumulated carbon from the ring grooves and oil control ring holes 1 Place...

Page 104: ...ankshaft The piston pin should be a push fit in the piston 6 Install the other circlip with the gap facing up or down and tang outward See Caution with Step 3 above Push the piston pin in both directi...

Page 105: ...to specifications 10 Install the two 6 mm bolts Cylinder Head Installation Clean the gasket surfaces on the cylinder head and cylinder Remove all traces of old gasket material Refer to disassembly pho...

Page 106: ...als and cam lobes Lubricate automatic compression release mechanism with clean engine oil 2 Install the camshaft with the lobes facing downward and the sprocket alignment pin facing upward 3 Disconnec...

Page 107: ...ft centerline B 6 Install the sprocket on the camshaft Apply Loctite 242 PN 2871949 to the cam sprocket bolts and torque to specifications 7 Verify TDC mark in timing inspection hole and alignment pin...

Page 108: ...man 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Camshaft Timing Illustration Dots Crankshaft to Camshaft Centerline Sprocket Alignment Pin TDC mark Rotation Do Not Use Adva...

Page 109: ...ant to the crankshaft bushing 2 Install a new O Ring in the oil passage recess in the crankcase 3 Apply Crankcase Sealant PN 2871557 or an equivalent sealer to the stator plate outer surface and insta...

Page 110: ...valves according to the valve adjustment procedure found in Chapter 2 Maintenance 8 Apply clean engine oil liberally to the valve springs cam chain rocker arms and camshaft 9 Place a new rocker cover...

Page 111: ...through the rope 3 Remove handle from the rope and allow spring tension on recoil to relax NOTE The handle must seal tightly on the recoil housing to prevent water from entering 4 Remove center bolt f...

Page 112: ...plete recoil assembly 1 Route rope through guide bushing in recoil housing and into reel Tie a secure knot in end of the rope 2 Wind rope counterclockwise onto the reel as viewed from ratchet side of...

Page 113: ...ner or breather system Improperly assembled air intake system Restricted engine breather system Oil contaminated with fuel Restricted oil tank vent Engine Engine Turns Over But Fails to Start No fuel...

Page 114: ...ion Fouled spark plug or incorrect plug or plug gap Carburetion faulty lean condition Exhaust system air leaks Ignition system faulty Spark plug cap cracked broken Ignition coil faulty Ignition or kil...

Page 115: ...NOTES ENGINE 3 60...

Page 116: ...FUEL SYSTEM 4 1 CHAPTER 4 FUEL SYSTEM 4 CARBURETION SYSTEM 4 3 ELECTRONIC FUEL INJECTION SYSTEM EFI 4 25...

Page 117: ...4 2 FUEL SYSTEM...

Page 118: ...ARTER SYSTEM CHOKE OR ENRICHMENT 4 8 PILOT IDLE AND SLOW SYSTEM 4 9 MAIN SYSTEM 4 9 FLOAT SYSTEM 4 10 PILOT SCREW 4 10 AIR FUEL MIXTURE RATIO 4 11 JET NEEDLE 4 11 NEEDLE JET 4 11 THROTTLE OPENING VS F...

Page 119: ...ance reliability and easier starting Special Tools SPX Corporation 1 800 328 6657 or http polaris spx com CAUTION A main jet that is too small will cause a lean operating condition resulting in seriou...

Page 120: ...etor Exploded View 1 of 2 Table 4 1 Carburetor Components REFERENCE DESCRIPTION REFERENCE DESCRIPTION A Jet Needle J Throttle Control Cover Plate B Diaphragm Assembly K Carburetor Body C Needle Jet L...

Page 121: ...arburetor Components REFERENCE DESCRIPTION REFERENCE DESCRIPTION A Throttle Plate Shaft Retaining Components J Float Bowl O Ring B Pilot Jet K Float Bowl C Needle Valve Assembly L Float Bowl Drain Scr...

Page 122: ...er than atmospheric Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward raising the slide against spring pressure Carburetor Component Function System Main Components M...

Page 123: ...nd be properly routed This allows fuel to flow in the proper amount and prevents contaminants from entering the carburetor Starter System Choke or Enrichment When the choke cable 1 is activated the st...

Page 124: ...lot screw and discharged into the main bore through pilot outlet 7 Main System As throttle valve 1 is opened engine speed rises and this increases negative pressure in the venturi Consequently the vac...

Page 125: ...e valve unseats itself to allow fuel into the chamber In this manner the needle valve releases and shuts off fuel alternately to maintain a constant fuel level inside the float chamber Pilot Screw The...

Page 126: ...into the upper portion and is tapered from approximately the middle of the needle to the lower end The top is fixed to the center of the throttle valve by the needle clip and the tapered end extends...

Page 127: ...uretor diaphragm chamber cover with a ratchet style screwdriver DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged 2 Remove float bowl Remove the float pin screw...

Page 128: ...eedle contacts the needle jet and is the most likely wear point If jet needle shows signs of wear replace both the needle and needle jet to prevent a rich condition TIP A worn needle jet is difficult...

Page 129: ...sure the tab E on outer edge of diaphragm is positioned properly in the carburetor body 3 Install the pilot mixture screw spring washer and O ring as an assembly Lubricate the O Ring with oil or ligh...

Page 130: ...en on left and right side Needle and Seat Leakage Test 1 Install the float bowl Invert the carburetor and install a Mity Vac PN 2870975 to the fuel inlet fitting Apply 5 PSI pressure to inlet fitting...

Page 131: ...olaris Sales Inc CARBUTATED FUEL TANK FUEL DELIVERY SYSTEM Fuel System Exploded View Align Fuel Pickup Sender as Shown Carburetor Mounting Impulse Hose Fuel Pump Fuel Filter To Carburetor Fuel Valve T...

Page 132: ...p must be replaced Fuel Filter Replacement Carbureted 1 Place shop towels and or a feel catch container under the fuel filter 2 Loosen the filter clamps and remove filter 3 Install new filter onto fue...

Page 133: ...If out of specification replace the fuel pump FUEL PICK UP SENDING UNIT REPLACEMENT CARB Fuel Pick up Sending Unit Replacement Fuel Sender Resistance Specifications Full 90 5 Empty 6 5 WARNING Always...

Page 134: ...ift the sending unit out of the fuel tank As the sending unit assembly is being removed be aware of float arm and pre filter Hold the float arm to the sending unit body as you lift and tilt the sendin...

Page 135: ...sure thread new PFA nut onto fuel tank and hand tighten Use care when starting PFA nut ensuring threads are properly aligned Verify orientation marks are still aligned between sending unit and fuel ta...

Page 136: ...0 and EFI Tractor Service Manual FUEL TANK VENT ROUTING NON INTL Fuel Tank Vent Hose Routing Proper fuel tank hose routing is important for proper fuel system operation Be sure the fuel tank vent hose...

Page 137: ...RPM drops quickly or is at high RPM the air valve closes During idle through mid range RPM the air valve is open and air is drawn into the from the PVT intake duct The air valve assembly B opens and c...

Page 138: ...inspect intake duct Air filter dirty plugged Electric choke inoperative Incorrect pilot air fuel screw adjustment Faulty inlet needle and seat Faulty inlet needle seat O Ring Float level too high Poo...

Page 139: ...NOTES CARBURATION AND FUEL SYSTEM 4 24...

Page 140: ...G PROCEDURE 4 37 FUEL LINES 4 38 QUICK CONNECT REMOVAL INSTALLATION 4 38 ELECTRONIC CONTROL UNIT ECU 4 38 OPERATION OVERVIEW 4 38 ECU REPLACEMENT 4 39 ECU SERVICE 4 39 FUEL PUMP ASSEMBLY 4 40 OPERATIO...

Page 141: ...57 ECU REPLACEMENT 4 57 GUIDED DIAGNOSTIC AVAILABLE 4 57 DIGITAL WRENCH COMMUNICATION ERRORS 4 58 DIGITAL WRENCH DIAGNOSTIC CONNECTOR 4 58 DIGITAL WRENCH VERSION AND UPDATE ID 4 59 DIGITAL WRENCH UPD...

Page 142: ...rench PU 43506 Fuel Pressure Test Kit PU 48838 Fuel Pressure Test Valve Kit 2201519 Throttle Position Sensor Tester PU 47471 Digital Wrench SmartLink Kit PU 50326 Fuel Pump Service Tool WARNING Gasoli...

Page 143: ...unicate between the vehicle ECU and the Digital Wrench diagnostic software Polaris dealers can also order separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable P...

Page 144: ...s normally closed and the slide valve E in the air control body is closed As the throttle opens and engine RPM increases the increase in vacuum opens the slide valve E allowing more air to be drawn in...

Page 145: ...ring stop and spring verifying the stop is firmly seated in the guillotine slide Install the diaphragm cover and screws Tighten sufficiently 4 Insert the assembly onto the connection tube leading to t...

Page 146: ...Manual Copyright 2011 Polaris Sales Inc Exhaust System The exhaust system is typical of Sportsman ATVs with an extra shield installed per regulations Maintain the exhaust canister according to the ma...

Page 147: ...m may be used without damaging system or engine components Do not use dielectric grease on sealed connectors connectors with a rubber grommet as it may displace the rubber seal and allow contaminants...

Page 148: ...trol Unit ECU 2 Manifold Absolute Pressure Sensor MAP 3 Intake Air Temperature Sensor IAT 4 Idle Air Control IAC 5 Crankshaft Position Sensor CPS inside cover 6 Fuel Injector 7 Fuel Rail 8 Fuel Filter...

Page 149: ...Absolute Pressure Sensor MAP Located in front of the throttle body on top of the intake track 4 Intake Air Temperature Sensor IAT Located under the seat in the rear of the airbox 5 Throttle Body Loca...

Page 150: ...track near the spark plug 10 Fuel Rail Located above the intake track near the fuel injector and spark plug 11 Fuel Filter Located in the fuel tank on the fuel pump asm 12 Fuel Pump Regulator Gauge Se...

Page 151: ...Service Manual Copyright 2011 Polaris Sales Inc FUEL SYSTEM AND FUEL TANK Fuel System and Fuel Tank Exploded View Fuel Tank Fuel Filter 30 micron Fuel Pump Pressure Regulator Unit Fuel Supply Rail In...

Page 152: ...nds depending on fuel requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle The total amount of fuel needed for one firing of a cyl...

Page 153: ...ut signals to the programmed maps in its memory and determines the appropriate fuel and spark requirements for the immediate operating conditions The ECU then sends output signals to set the injector...

Page 154: ...connector from the ECU using great care not to damage the harness connector or locking mechanism NOTE Should the black slider become broken replacement parts are available 3 To install reverse the pro...

Page 155: ...TEST NOTE 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 ar...

Page 156: ...and listen for the pump to activate NOTE If the pump starts repeat steps 1 and 2 to verify correct pressure NOTE If the pump still does not operate check for correct ECU operation by plugging in a kn...

Page 157: ...ack of tank 4 Reinstall the PVT intake duct fuel tank vent line front cab assembly and side panels NOTE Properly route the gas tank vent lines use tape to secure the vent line in place See Pic 1 5 Rec...

Page 158: ...onnect fuel line from the fuel pump NOTE A small amount of fuel may come out of the fuel line or tank Properly drain fuel into a suitable container 6 Be sure the top of the fuel tank is clean If it re...

Page 159: ...el tank from the vehicle and rinse it with a small amount of clean fuel Do not use water or any other chemicals to remove debris 11 Remove new fuel pump assembly gasket and PFA nut from packaging Use...

Page 160: ...ump outlet IMPORTANT Be sure to engage the retainer on fuel line until it snaps into place Pull on fuel line lightly to confirm connection 21 Connect the fuel pump electrical harness 22 Install the lo...

Page 161: ...fuel pump filter The filter is located inside the tank as part of the fuel pump assembly Fuel Filter Service The in tank filter is non serviceable Tank flushing to remove sediments may temporarily re...

Page 162: ...me contributing factors to injector clogging include dirty air filters higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged...

Page 163: ...icates 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 185W 20 at room tempera...

Page 164: ...nitor the MAP sensor and cease the initial start up program Map Sensor Test MAP sensors are a non serviceable item If it is faulty it must be replaced This sensor requires a 5 Vdc input to operate the...

Page 165: ...nt 1 Disconnect engine harness from sensor 2 Using a suitable tool remove the sensor from the grommet 3 Lightly coat the grommet with soapy water and install a new sensor using a twisting motion to pr...

Page 166: ...processed by the ECU and compared to the internal pre programmed maps to determine the required fuel and ignition settings for the amount of engine load Throttle Position Sensor Test The throttle posi...

Page 167: ...h no jumps or decreases when the throttle is applied If the TPS does not function correctly replace it TPS Tester Correct Reference Voltage A 5 volt reference voltage signal from the test harness is r...

Page 168: ...as this could cause unnecessary throttle plate to throttle body interference and or damage Set up the TPS Test Adapter Harness 2201519 Verify that the 9 volt battery is new Figure 2 NOTE Applies to 5...

Page 169: ...rmine when to activate the fan during operation If for any reason the engine temperature sensor circuit is interrupted the fan will default to ON Engine Temperature Sensor Test Polaris dealers can tes...

Page 170: ...plug TPS setting incorrect Injector failure Failed Sensor or disconnected wiring Throttle stop screw tampering replace throttle body POOR IDLE Symptom Idle Too High If greater than 1300 RPM when engin...

Page 171: ...ronization Yes 22 TPS Circuit Sensor Low Yes 22 TPS Circuit Sensor High Yes 25 Transmission Input Invalid Gear Yes 26 Vehicle Speed Sensor Implausible Yes 31 System Voltage Low Yes 31 System Voltage H...

Page 172: ...D ECU Replacement Although the need for ECU replacement is unlikely a specific replacement procedure is required to ensure that all essential data contained within the original ECU is transferred to t...

Page 173: ...stic connector is located under the front storage box access cover Follow these steps to connect the diagnostic interface cable to the vehicle to allow Digital Wrench use 1 Assemble the SmartLink Modu...

Page 174: ...nch see Digital Wrench Updates IMPORTANT Always operate with the latest update Digital Wrench Updates Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Digital W...

Page 175: ...the icon to start the update process NOTE Do not run or open the file from where they are Select save and download them to your PC before running the install 8 When the update is complete the version...

Page 177: ...ne dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and contain the most recent calibrations see Digital Wrench Updates CLOSE NO...

Page 178: ...to the ECU then click the Continue icon to proceed to the Integrity Check and obtain a Request Code 8 Copy CTRL C the Request Code that will be required on the dealer website in the next step DO NOT C...

Page 179: ...will appear in the upper left corner of the screen Copy CTRL C this key exactly as it appears 13 Enter or paste CTRL V the Authorization Key in the box located on the Digital Wrench screen Click the...

Page 180: ...65 500 EFI FUEL SYSTEM 4 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc TROUBLESHOOTING DIAGRAMS EFI CIRCUIT Power On EFI CIRCUIT Crank Position Sensor...

Page 182: ...4 67 500 EFI FUEL SYSTEM 4 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc EFI CIRCUIT Idle Air Control EFI CIRCUIT Throttle Position Sensor...

Page 183: ...68 500 EFI FUEL SYSTEM 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc EFI CIRCUIT Manifold Absolute Pressure Sensor EFI CIRCUIT Engine Coolant Temperatu...

Page 184: ...4 69 500 EFI FUEL SYSTEM 4 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc EFI CIRCUIT Air Temperature Sensor EFI CIRCUIT Malfunction Indicator Light...

Page 185: ...NOTES 500 EFI FUEL SYSTEM 4 70...

Page 186: ...B ASSEMBLY 5 9 FRONT BUMPER ASSEMBLY 5 10 REAR RACK ASSEMBLY 5 11 REAR CAB AND SEAT ASSEMBLY 5 12 REAR STORAGE BOX ASSEMBLY 5 13 WINCH AND FRONT BUMPER MOUNTING 5 14 HEADLIGHT POD EXPLODED VIEW 5 15 5...

Page 187: ...Apply the decal COMPONENT FT LBS IN LBS NM Front Hub Nut 60 81 Front A Arm Attaching Bolt 37 50 Front A Arm Ball Joint Stud Nut 30 41 Handlebar Adjuster Block 14 23 Master Cylinder Clamp Bolt 45 55 5...

Page 188: ...enough pressure on the side cutters to lift 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 i...

Page 189: ...near the rear cab With a firm motion pull the panel outward 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 r...

Page 190: ...per 6 Remove the front storage box lid front rack from the vehicle 7 Reverse procedure for installation Foot Well Removal Installation 1 Remove the four plastic inserts A that secure the wheel well to...

Page 191: ...the upper front bumper by gently pressing down on the bumper and pulling up on the front fender 7 Remove the front bumper by gently the pulling the lower portion of the bumper away from the vehicle f...

Page 192: ...ount area 4 Remove the 4 screws C that attach the front cab to the frame in the front rack area 5 Remove the seat and side panels refer to the SIDE PANEL REMOVAL section 6 Remove the plastic inserts D...

Page 193: ...Y STEERING SUSPENSION 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Front Rack Storage Box Lid Assembly Front Rack Storage Box Lid Seal Latch Asm Cable...

Page 194: ...STEERING SUSPENSION 5 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Front Cab Assembly Front Cover Access Panel Side Cover Front Cab Splash Guards Sid...

Page 195: ...anual Copyright 2011 Polaris Sales Inc Front Bumper Assembly 5 16 18X1 3 4 X2 MAIN FRAME BUMPER FRAME BUMPER ASM FRONT FANG COVER RH RADIATOR SHIELD UPPER RADIATOR BRACKET LH RADIATOR SHIELD WINCH ACC...

Page 196: ...2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Rear Rack Assembly REAR RACK 14X1 3 4 X2 REAR RACK SUPPORT MAIN FRAME SPACER SPACER 5 16 18X1 3 4 X4 5 16 18X2 1...

Page 197: ...and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Rear Cab And Seat Assembly REAR CAB RH FOOTWELL LH FOOTWELL SEAT ASM SEAT LATCH RETAINER RUBBER MOUNTS LATCH SPRING RETAINER BRACKETS R...

Page 198: ...TEERING SUSPENSION 5 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Rear Storage Box Assembly PANEL FOAM STORAGE BOX DOOR GASKET LATCH DRAIN PLUG PLASTI...

Page 200: ...adlight F with adjuster Remove two screws securing bottom half of pod E Assembly Install bottom of pod onto handlebar and secure to brackets Install key switch choke cable and headlight Connect 12Vdc...

Page 201: ...ll spring preload before service 2 Remove the seat 3 Remove the fasteners and cross bolts from each end of the dampener assembly 4 Remove the dampener and install a new one 5 Install the cross bolts a...

Page 203: ...Steering Assembly Exploded View The 500 EFI Tractor is equipped with a steering locking mechanism to prevent theft or unauthorized use Refer to the standard torque specifications chart in Chapter 1 w...

Page 204: ...nt of the ATV 3 Align the pin A in the top block with 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...

Page 205: ...on The steering post arm bolt B points up the 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 N...

Page 206: ...l new A arm assembly onto vehicle frame Torque new bolts 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 s...

Page 207: ...pply heat to ease removal 12 Hold bolt J and 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...

Page 208: ...reely and easily from full left to full right without binding 8 Install front cab SUSPENSION Front Strut Cartridge Replacement NOTE Refer to illustration on following page 1 Hold strut rod and remove...

Page 210: ...Polaris Sales Inc Sportsman Rear Suspension Assembly Upper Control Arm Lower Control Arm Bushings Rear Compression Spring Preload Adjustment Cam Wheel Bearing Carrier Boot Shield 37 ft lbs 50 Nm 50 N...

Page 211: ...tsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Torsion Bar Exploded View Stabilizer Bar Stabilizer Bushing 17 ft lbs 23 Nm 30 ft lbs 40 Nm 30 ft lbs 40 Nm 50 Nm 37 ft lb...

Page 212: ...NOTES...

Page 213: ...E CLUTCH SERVICE NON EBS 6 13 EXPLODED VIEW NON EBS 6 13 CLUTCH DISASSEMBLY 6 14 DRIVE CLUTCH SPRING INSPECTION 6 15 SHIFT WEIGHT INSPECTION 6 15 SPIDER REMOVAL 6 16 BUTTON TO TOWER CLEARANCE INSPECTI...

Page 214: ...ch Puller 2870506 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 Drive Clutch Spider Removal and Install Tool 2870341 Roller Pin Tool 2870910 Clutch Bushing Replacement Tool Kit 2871226...

Page 215: ...ransmission 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 d...

Page 216: ...s and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs 3 Sheave Faces Clean and inspect for wear 4 PVT System Sealing Refer to appropriate illustrations on the followin...

Page 217: ...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 Towing...

Page 218: ...Polaris Sales Inc PVT EXPLODED VIEWS PVT Sealing And Ducting Components Drive Clutch Exploded Views EBS vs Non EBS Clutch Inlet Duct Clamps Boot Duct Clutch Cover Clutch Cover Seal Seal Retainer Brac...

Page 219: ...otation and remove drive belt See Drive Belt Removal 6 Install the Drive Clutch Holder PN 9314177 A 7 Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller PN 287050...

Page 220: ...ar inner cover bolts B to specification 7 Install clutch alignment washer s on transmission input shaft 8 Clean splines inside driven clutch and on the transmission input shaft 9 Apply a light film of...

Page 221: ...it can be installed in the same direction NOTE Belt is normally positioned so that part numbers are easily read 3 To remove drive belt put transmission in gear apply brake pull upward and rearward on...

Page 222: ...es A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and drive belt by operating at slower speeds during the 10 hour break in peri...

Page 223: ...ches the shaft bearing but has an excessive amount of clearance between the tool and stationary sheave the driven clutch will need to be moved in to correct the alignment Remove the driven clutch Remo...

Page 224: ...t remain between the inner and outer sheave of the driven clutch If proper belt deflection cannot be obtained measure drive belt width length and center distance of drive and driven clutch outlined in...

Page 225: ...ce Manual Copyright 2011 Polaris Sales Inc DRIVE CLUTCH SERVICE NON EBS Exploded View NON EBS Washers Bearing Spring Cover Bearing Bushing Lock Washer Bolt Flat Washer Cover Screws Button Pin Washers...

Page 226: ...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 where bu...

Page 227: ...ght The surface should be smooth and free of dents or gall marks Inspect the weight pivot bore and bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bo...

Page 228: ...u 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 R...

Page 229: ...not disassembled inspect as shown using a clutch holding tool to compress the moveable sheave The contact surface of the weight should be smooth and free of dents or gall marks 2 Remove shift weight...

Page 230: ...d in either direction continue with disassembly Clutch Inspection NOTE Remove cover spring and spider following instructions for drive clutch removal then proceed as follows 1 Remove the moveable shea...

Page 231: ...compare to specification Replace if worn or damaged Moveable Sheave Bushing Inspection Inspect the Teflon coating arrow on the moveable sheave bushing Inspect both sheaves for signs of wear grooving...

Page 232: ...the marks that were made earlier on spider aligns with X or the marks that were made earlier in moveable sheave 4 Torque spider to specification using the holding fixture and spider tool Torque with...

Page 233: ...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 where bushing rides for wear g...

Page 234: ...OTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of these washers 2 Inspect the Teflon coat...

Page 235: ...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 switch all buttons...

Page 236: ...nd thrustwasher 4 off shaft Replace as an assembly if worn damaged or if problems were noted 3 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specif...

Page 237: ...3M pad if needed One Way Clutch Inspection EBS 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...

Page 238: ...at were made earlier under weight 2 Install moveable sheave onto fixed sheave 3 Install spider spacers Use same quantity and thickness as were removed 4 Compress spider buttons for each tower and inst...

Page 239: ...Screw Torque 100 in lbs 11 25 Nm Engine Rotation Nut on trailing side EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 E...

Page 240: ...A B into center of sheave with A side toward sheave NOTE Use Bushing Tool PA 47336 8 Install nut C onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed U...

Page 241: ...tside of clutch cover insert removal tool Item 3 into cover bushing 4 With inside of cover toward vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller barrel to incr...

Page 242: ...2 Remove snap ring retainer 3 Note the location of the spring and remove helix 4 Note the location of the spring in the moveable sheave and remove the spring 5 Check alignment of tabs on spring Repla...

Page 243: ...n between the sheaves when adjusting belt deflection 8 Inspect the Teflon coating on the moveable sheave bushing 9 Inspect driven clutch faces for wear or damage 10 Clean and inspect splines on helix...

Page 244: ...apply heat directly on bushing until tiny smoke tailings appear 5 Working from the top install Driven Clutch Bushing Removal Tool 5 PN 5020631 into the center of clutch sheave with smaller diameter to...

Page 245: ...nstall sheave onto puller with new bushing upward as shown Install Puller Adapter 10 PN 5020633 4 Install nut onto puller rod and hand tighten against installation tool 5 Turn clutch sheave counterclo...

Page 246: ...oveable assembly has several different spring locations which affect clutch shifting and RPMs The greatest amount of spring tension will raise engine RPMs during clutch upshift and allow quicker backs...

Page 247: ...E EBS Driven Clutch Exploded Views EBS 1 Torx Screw 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 Spri...

Page 248: ...the position of the shaft cam cover and sheave before disassembly or use the X s on the components for reference This will aid in reassembly and helps to maintain clutch balance after reassembly 3 Re...

Page 249: ...late D and spider dampener E Inspect the spider dampener E for wear and replace if needed 7 Remove the E clips F washers G and the clutch rollers H Inspect the rollers for wear replace if worn 8 Remov...

Page 250: ...spin smoothly replace it To replace the bearing remove the snap ring from the end of the shaft and press the bearing off the shaft 13 Inspect the cam helix assembly bushing for wear If the bushing is...

Page 251: ...fully seated install a new snap ring 2 Install the shaft and bearing assembly into the outer sheave NOTE Press only on the outer race of the bearing during installation to prevent from damaging the be...

Page 252: ...all the spring over the shaft 8 Install the clutch rollers D onto each side of the outside spider Install the washers E and E clips F to secure the rollers The rollers should spin freely 9 Install the...

Page 253: ...ider are aligned Once the spider passes the retaining ring notch on the shaft install the retaining ring 13 Install the cam helix assembly over the shaft Line up the X on the cam X on spider and X on...

Page 254: ...Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBS Bushing Removal 5132028 1 Instructions 9915111 Additional Special Tools Qty Par...

Page 255: ...tighten by hand Turn puller barrel for further tension if needed 7 Turn clutch sheave counterclockwise until bushing is removed and sheave comes free 8 Remove nut C left hand thread from puller rod a...

Page 256: ...rate Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slipage Install correct recommended spring Install correct...

Page 257: ...r different terrain as outlined in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines f...

Page 258: ...NOTES CLUTCHING 6 46...

Page 259: ...7 17 ADC GEARCASE EXPLODED VIEW 7 18 ADC OPERATION 7 19 FRONT GEARCASE DIAGNOSIS 7 20 COIL TESTING 7 21 ADC DIFFERENTIAL HYDRAULIC CIRCUIT BLEEDING 7 21 DISASSEMBLY INSPECTION 7 22 ADC GEARCASE PISTO...

Page 260: ...rews 17 23 1 9 2 5 ADC Cover Screws 7 11 9 4 14 9 ADC Bleed Valves 80 9 Item Specification Steel Front and Rear Wheel Nuts 27 ft lbs 37 Nm Aluminum Front and Rear Wheel Nuts 30 ft lbs 1 4 Turn 41 Nm 1...

Page 261: ...erances 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 qu...

Page 262: ...the roller pin from the front prop shaft Use the Roller Pin Removal Tool PN 2872608 7 Remove bolts securing the bottom of housing to the skid plate frame Bolts and fluid drain plug are accessible thr...

Page 263: ...nstall gearcase reverse removal procedures Use a new roll pin in front prop shaft 2 Torque mounting bolts in skid plate to 30 ft lbs 41 Nm 3 Add the proper lubricant to the front gearcase Check drain...

Page 265: ...ing Gear Assembly 1 36 Oil Seal 1 13 Bushing non serviceable see parts book 1 37 Drain Plug TORQUE 8 30 ft lbs 11 40 Nm 1 14 Input Cover 1 38 Dowl Pin non serviceable see parts book 1 15 O ring square...

Page 266: ...e ring gear and roll cage are spinning vehicle is moving the energized coil and armature plate will apply drag to the roll cage that indexes the rollers inside the ring gear to an engagement position...

Page 267: ...assembly 3 Remove the outer cover plate assembly 4 Remove the output hub assembly from the outer cover plate Inspect the bearing and contact surfaces of the output hub for signs of wear or damage Rep...

Page 268: ...and flat spots Inspect the roll cage B for damage or cracks The rollers must slide up and down freely within the roller cage surfaces 10 Inspect the ring gear C for inconsistent wear patterns or dama...

Page 269: ...t cover is replaced or the back lash pad screw is removed See the FRONT GEARCASE ASSEMBLY procedure later in this chapter for details on backlash setting 14 Remove the bolts retaining the input shaft...

Page 270: ...ting 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 side to side 4 Insta...

Page 271: ...by rotating in both directions to ensure the spring and retainer are installed properly 12 Be sure the armature plate tabs are fully engaged into the roll cage assembly and are resting on the cut gro...

Page 272: ...ce To test 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...

Page 273: ...insert that is pressed into the gearcase cover The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If the top of the coil is above the surface of...

Page 274: ...Using a hex wrench turn the back lash screw out 3 4 turns Re apply Loctite 262 onto the bottom screw threads 3 Turn the screw in until it is lightly seated then turn the screw out 1 4 turn 4 Set the...

Page 275: ...reating a magnetic field This magnetic field attracts an armature plate keyed to a roller cage inside an external cam ring gear The rpm difference between the input shaft and front axles forces the ro...

Page 276: ...nector 1 6 Vent 1 22 O ring Pump 2 7 Cap Bleed Screw 2 23 Seals 3 8 Output Hub Sub Assembly 1 24 Bleeder Valve 2 9 Cover Assembly 1 25 Cam Assembly 1 10 Cover Bracket 1 26 Armature Plate 1 11 Gear Cas...

Page 277: ...set to 4x4 ADC a 12 Vdc current is present at the input shaft coil 1 Operation is controlled by the ECU grounding and ungrounding the coil The coil s magnetic field attracts a splined armature plate...

Page 278: ...nside the other If only one band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 4 A band with an interrupted wear mark may indicate a warped pl...

Page 279: ...y be encountered with inadequate bleed of the hydraulic circuit 5 Begin the bleeding process by filling reservoir to MAX line with clean Polaris ADC oil 6 Locate bleeder valves found on either side of...

Page 280: ...ver plate assembly Remove and inspect the cover o ring A Replace items as required NOTE Thrust bearing 2 located between the two output assemblies is pressed into the clutch pack and is not removable...

Page 281: ...rs will exit the housing with force 8 Remove and inspect the bearing surfaces of the second output clutch Visually inspect the clutch plate area If plates are steel on steel or if the friction materia...

Page 282: ...t Gearcase Diagnosis on page 7 20 13 Inspect the magnetic coil 1 in the outer cover plate assembly Inspect the backlash pad 2 for excessive wear NOTE See FRONT GEARCASE DIAGNOSIS in this chapter NOTE...

Page 283: ...for wear or damage Replace component as required 18 Remove the snap ring retaining the input shaft assembly 19 Remove the input shaft assembly Inspect the pinion gear 1 for chipped broken or missing...

Page 284: ...photo 3 Remove and discard the inner and outer o rings from the piston assembly NOTE Never re use o rings Always replace with new 4 Coat new piston and o rings with a moderate amount of white lithium...

Page 285: ...t below the cavity edge 7 Repeat procedure for the other gearcase half NOTE Verify that the o rings are seated properly and that no o ring shavings exist outside of the piston area which is an indicat...

Page 286: ...acket Torque to specification 8 Install a new seal 1 in the outer cover plate assembly Install a new o ring on the backlash pad 2 stem NOTE Ring gear backlash 2 is set at the factory No adjustment is...

Page 287: ...g gear roller cage assembly 2 11 Install the armature plate Verify the armature plate tabs align with tab recesses in the roll cage and ring gear 12 Install new cover o ring and ADC passage o ring arr...

Page 288: ...e screws to specification 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 removed 1...

Page 289: ...urn Perform the step 16 again Repeat this procedure until the pinion shaft rotates smoothly 4 times 1 revolution of ring gear FRONT DRIVE CV SHAFT Inspection Check the front and rear driveshaft CV boo...

Page 290: ...b nut and hub assembly 9 Remove cotter pin and nut from lower A arm ball joint 10 Remove lower A arm from ball joint using a ball joint fork tool 11 Pull strut assembly out while pivoting the CV drive...

Page 291: ...with soft faced hammer 2 Install drive shaft in strut 3 Install lower ball joint torque nut to specification and install new cotter pin 4 Install hub and tighten hub nut to specification 5 Install br...

Page 292: ...lock the parking brake Remove rear hub cap 2 Remove cotter pin A 3 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...

Page 293: ...ress NOTE Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 3 Inspect bearing NOTE Due to extremely c...

Page 294: ...lower control arm bushings into place securing corner housing 3 Install and torque both lower control arm bolts 4 Lift bearing carrier until top aligns with upper control arm Install and torque upper...

Page 295: ...ed REAR DRIVE CV SHAFT Inspection Check the front and rear driveshaft CV boots for any tears or leaking grease If the driveshaft boot loses all grease CV joint failure will occur Removal 1 Remove rear...

Page 296: ...l bolt to upper control arm Torque bolt to specification 5 Install hub flat washer domed washer domed side out and nut Torque center hub nut to specification Install new cotter pin and hub cap 6 Insta...

Page 297: ...TE Refer to your parts manual for the proper replacement parts Compression Inner CV Inner Boot Outer Boot Outer CV Joint Drive Axle Components Drive Boot Replacement Kits Prop Shaft Components Clamps...

Page 298: ...suspension components Never use a hammer 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 jo...

Page 299: ...ach ball Severe pitting galling play between the ball and its cage window any cracking or damage to the cage pitting or galling or chips in raceways call for joint replacement NOTE Shiny areas in ball...

Page 300: ...t lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 19 Install and tighten the large clamp using the Axle Boot Clamp Tool 8700226 or PU 48951 20 While...

Page 301: ...a soft faced hammer or brass drift strike the inner race of the joint to drive the joint off the drive shaft Be sure to tap evenly around the joint to avoid binding IMPORTANT Tap on inner race only 6...

Page 302: ...ase the joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face...

Page 303: ...grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 20 Install and tighten the small clamp using the Axle Boot Clamp Tool 8700226 or PU 48951 21 Pull out on the drive...

Page 304: ...ion output shaft rear only Slide prop shaft back and away from housing then pull sharply forward to remove from transmission shaft 2 For installation reverse the removal procedure NOTE If removing rea...

Page 305: ...eplaced Note orientation of grease fitting if equipped and mark inner and outer yoke for correct re positioning during installation 2 Support inner yoke as shown and drive outer yoke down bearing cap...

Page 306: ...ble arbor fully seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled are assembled 3 Install snap ring to contain bearing cap just installed...

Page 307: ...FRAME MOUNT 8 4 TRANSMISSION REAR STABILIZER MOUNTS 8 5 TRANSMISSION CONTROL ARM BRACKET MOUNTS 8 6 SHIFT LINKAGE INSPECTION 8 7 GEAR SELECTOR REMOVAL 8 7 TRANSMISSION REMOVAL 8 7 TRANSMISSION INSTALL...

Page 308: ...e Bolts 25 30 36 43 Bell Crank Nut 12 18 17 26 Transmission Fill Drain Plug 20 25 29 36 Trans Mounting Bolts 37 40 50 57 Gear Sector Cover 8 12 11 17 Oil Deflector Screws 20 30 2 3 6 Snorkel Torx Scre...

Page 309: ...2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Transmission Frame Mounts Transmission Frame Mount Locations A A A B B T A Frame Long Bolts 37 ft lbs 50Nm B Sid...

Page 310: ...EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Transmission Upper Frame Mount Transmission Upper Frame Mount Location UPPER MOUNT BRACKET B A T A UpperBracket to FrameFasteners 20ft lbs...

Page 311: ...aris Sales Inc Transmission Rear Stabilizer Mounts Transmission Rear Stabilizer Mounts REAR STABILIZER STABILIZER MOUNTS TO UPPER FRAME HOLES A C C B T A Stabilizer to Frame Fasteners 20ft lbs 27Nm B...

Page 312: ...tor Service Manual Copyright 2011 Polaris Sales Inc Transmission Control Arm Bracket Mounts Transmission Control Arm Bracket Mounts CONTROL ARM BRACKET A B B CONTROL ARM BRACKET X X X T A Bracket Moun...

Page 313: ...nsmission 5 Disconnect transmission vent hose from the nozzle 6 Disconnect shift rod end from transmission bellcrank 7 Remove PVT outer cover drive and driven clutches and the inner PVT cover refer to...

Page 314: ...the transmission stabilizer assembly brackets to retain the rear suspension 7 Install the stabilizer bar links and shocks into the upper control arms 8 Install PVT system Refer to Chapter 6 PVT sectio...

Page 315: ...ansmission Exploded View FOR REASSEMBLY Apply White Lithium Based Grease Apply Polaris Crankcase Sealant Apply Loctite to the bolt threads 12 18 ft lbs 16 24 Nm 25 30 ft lbs 34 41 Nm 10 14 ft lbs 14 1...

Page 316: ...ing 59 1 Snorkel Shaft 16 1 Shim 60 1 Ball Bearing 17 1 Ball Bearing 61 1 Retaining Ring 18 1 Center Drive Shaft 62 1 Snorkel Tube 19 1 Retaining Ring 63 5 Screw 20 1 Thrust Washer 64 1 Shim 21 1 Gear...

Page 317: ...5 Remove the E clip C that retains the gear selector switch D and remove the switch 6 Remove the sector cover bolts E and remove the sector cover F NOTE Removal can be aided by using your thumbs to pr...

Page 318: ...ice limit and should be replaced along with the chain tensioner shoe 13 Remove the cam chain tensioner spring O Slide the cam chain tensioner shoe P pins Q and cam chain tensioner cam N from the assem...

Page 319: ...flector T 16 Using a T27 Torx driver remove the screws that secure the output gear U 17 Remove the shift drum V from the gearcase by moving the drum up and to the right to clear the shift shaft 18 Rem...

Page 320: ...puller see Figure 8 1 23 Remove the 33T gear and needle bearing from the reverse shaft see Figure 8 1 24 The reverse shaft should slide out of the silent chain to separate the assembly 25 Remove the...

Page 321: ...ew located inside the gearcase 31 Remove the seal from the snorkel shaft to access the snorkel tube for removal 32 Using the Snorkel Tool PA 50231 loosen and remove the snorkel tube and shaft assembly...

Page 322: ...the remaining bearing on the snorkel shaft remove the retaining ring and press the bearing off 38 Remove all seals from the gearcase halves and clean the cases in preparation for assembly Snorkel Outp...

Page 323: ...ws A that secure the output gear assembly Torque the screws to specification 7 Tighten the snorkel tube until it is lightly seated using the snorkel tool PA 50231 Turn the output shaft to prevent bind...

Page 324: ...k the output shaft gear backlash again by feel If the output shaft lash appears to be too tight rotate the snorkel shaft counterclockwise to the next notch 11 Once the backlash is set apply Loctite 24...

Page 325: ...rum Replace the O ring on the end of the shift drum and lubricate it before assembly 3 Stretch the silent chain on a flat surface and measure the length of 8 pitches in a minimum of three places on th...

Page 326: ...to their respective recess in the gearcase 6 With all the components in the correct position install the 4 output gear assembly retaining screws Apply Loctite 242 to the threads of the screws Torque t...

Page 327: ...ace 9 Tensioner Installation NOTE Case halve mating may be difficult due to tensioner pressure on the silent chain during installation Release tension at the ratcheting cam to aid case half installati...

Page 328: ...Guide PN 2871699 to install the seals into the gearcase halves refer to the following illustration to identify the seals needing replacement 12 Thoroughly clean the shift shaft housing Be sure the tr...

Page 329: ...ling the sector cover 18 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface Install the sector cover and torque the bolts to specification 19 Install the bel...

Page 330: ...NOTES TRANSMISSION 8 24...

Page 331: ...OREST 500 INTL FRONT CALIPER ASSEMBLY 9 11 FRONT MASTER CYLINDER ALL MODELS 9 12 REMOVAL 9 12 INSTALLATION 9 12 FRONT BRAKES 9 13 PAD REMOVAL 9 13 ASSEMBLY 9 14 BRAKE BURNISHING PROCEDURE 9 15 FRONT B...

Page 332: ...37 Rear Brake Switch 12 15 16 21 Caliper Mounting Bolts 18 0 24 Sportsman Caliper Slide Pins 30 35 41 48 Rear Master Cylinder to Frame Bolts 8 11 FRONT BRAKE CALIPER Sportsman and Touring ITEM STANDA...

Page 333: ...e 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 cau...

Page 334: ...age This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust WARNING Once a bottle is opened use what is necessary and discard the rest in accordance...

Page 335: ...ly on fitting NOTE Fluid may be forced from supply port B when brake lever is pumped Place diaphragm C in reservoir to prevent spills Do not install cover See Illustration above 6 Slowly pump the brak...

Page 336: ...o specification 15 Field test machine at low speed before putting into service Check for proper braking action and lever reserve With lever firmly applied lever reserve should be no less than 1 2 1 3...

Page 337: ...r Cylinder Cover Screws 7 in lbs 0 79 Nm 2 Banjo Style 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...

Page 340: ...r Caliper Assembly non INTL A Socket Set Screw B Bleeder Screw C Caliper Asm D Boot E Square O rings F Piston G Caliper Mount H Brake PAds A B C D E F G H Disc brake caliper lube 3 3 Apply Polaris DOT...

Page 341: ...Rear Housing F Seals G Piston H Slide Pins I Bushings J Seal K Bracket L Pad M Front Housing N Retaining Clips 3 Apply Polaris DOT approved Brake fluid to component A B C D E F G H I J K L M N 3 3 30...

Page 342: ...on each side of banjo fitting on the brake line and torque banjo bolt to specification 3 Fill reservoir with DOT approved brake fluid NOTE To speed up the brake bleeding procedure the master cylinder...

Page 343: ...t 5 Push caliper piston into 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 wh...

Page 344: ...ubricate mounting bracket pins with a light film of disc brake caliper lube and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with fricti...

Page 345: ...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 m...

Page 346: ...moving the brake disc mounting bolts 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 C...

Page 347: ...line 2 Push upper pad retainer pin inward and 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 th...

Page 348: ...and pads as outlined for brake pad replacement in this 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...

Page 349: ...lation 5 Install caliper on hub strut and torque mounting bolts to specification 6 Install brake line and torque the banjo bolt to specification 7 Install the adjuster screw and turn until stationary...

Page 350: ...er be careful not to damage brake line Support caliper 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 NOT...

Page 351: ...as been built up Maintain at least 1 2 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 co...

Page 352: ...caliper off of disc NOTE When removing caliper 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 instal...

Page 353: ...air from entering the master cylinder 6 It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Brake Burnishing Procedu...

Page 354: ...ke line from caliper 3 Remove the two caliper mounting 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...

Page 355: ...sc and pads as outlined for brake pad replacement in this 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 clea...

Page 356: ...re removal 2 Using a flare nut wrench remove hand brake inner and auxiliary brake outer lines arrows Place a container to catch brake fluid draining from brake lines 3 Remove the two caliper mounting...

Page 357: ...evere corrosion or galling and replace if necessary 11 Inspect surface of caliper piston for nicks scratches or damage and replace if necessary Assembly 1 Install new O rings in the slide bolt bushing...

Page 358: ...led on caliper mount 4 Install caliper and torque mounting bolts to specification 5 Install brake line and tighten securely with a line wrench Torque the brake lines to the proper torque specification...

Page 359: ...ident 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...

Page 360: ...ight 2011 Polaris Sales Inc REAR MASTER CYLINDER Sportsman 500 HO Touring Exploded View Non Intl 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...

Page 361: ...reservoir Make sure the brake lever and pedal returns freely and completely Adjust stop pin on caliper if applicable after pad service Check and adjust master cylinder reservoir fluid level after pad...

Page 362: ...rake fluid properly 3 Remove the two bolts that secure the rear master cylinder to the frame Replace parts as needed 4 To install the rear master cylinder mount the master cylinder to the frame and to...

Page 363: ...s needed 4 To install the rear brake master cylinder mount the master cylinder to the mount plate and torque bolts to specification 5 Reinstall the brake line and torque the banjo bolt to specificatio...

Page 364: ...system brake fluid contaminated Caliper disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incorrectly adjusted lever Incorrectly adjusted st...

Page 365: ...ANT TEMPERATURE SENSOR EFI 10 18 COOLANT TEMPERATURE FAN SWITCH H O 10 19 GEAR POSITION INDICATOR SWITCH 10 19 TEST DIAGRAM 10 19 ELECTRONIC THROTTLE CONTROL ETC SWITCH 10 20 OPERATION OVERVIEW 10 20...

Page 366: ...TIFICATION 10 45 BATTERY CONDUCTANCE ANALYZER 10 45 BATTERY ACTIVATION CONVENTIONAL 10 46 BATTERY TERMINALS BOLTS 10 46 CONVENTIONAL BATTERY INSPECTION REMOVAL 10 47 CONVENTIONAL BATTERY INSTALLATION...

Page 367: ...s SPX Corporation 1 800 328 6657 or http polaris spx com Ignition System Basic Electrical Components PART NUMBER TOOL DESCRIPTION PV 43568 Fluke 77 Digital Multimeter 2870630 Timing Light 2870836 Batt...

Page 368: ...uded in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used for when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to...

Page 369: ...rning or the No 10 Pin could be grounded B The speedometer features numbers in Mile Per Hour MPH and Kilometers Per Hour KPH C The Rider Information Center performs a number of functions See Illustrat...

Page 370: ...BLESHOOTING for help with diagnosis of overheating 4 High Low Battery Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery...

Page 371: ...out of the diagnostic mode and into standard display mode NOTE To leave the diagnostic mode turn the key switch off and on 1 Turn the key switch off and wait 10 seconds 2 Set the park brake and shift...

Page 372: ...s to provide the consumer and dealer with a convenient reminder for routine maintenance When the ATV leaves the factory this feature is set at 50 hours Once the service interval mode is set with the h...

Page 373: ...imately 7 seconds until the word OFF appears in the Rider Information Center The service interval is now OFF To enable turn on the service interval mode repeat the steps above in Setting Service Inter...

Page 374: ...CU 1 Verify the ATV key switch is off and the transmission is in park 2 Turn the key switch ON and OFF 3 times within 5 seconds and leave the key switch in the ON position on the third turn 3 The word...

Page 375: ...a soap and water mixture onto the outer surface area of the instrument cluster This will help the instrument cluster slide into the pod assembly more easily 2 Be sure the rubber grommet inside the pod...

Page 376: ...10 12 ELECTRICAL 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING TEST 1 No All Wheel Drive...

Page 379: ...d Sensor Testing Special Tools Required Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect the 3 wire harness from the speed sensor and remove the sensor from the...

Page 380: ...10 16 ELECTRICAL 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc TEST 7 Fuel Gauge Display Not Working TEST 8 Shift Indicator Not Working...

Page 381: ...d if coolant level is low or if air is trapped in the cooling system Be sure cooling system is full and purged of air Refer to Maintenance Chapter 2 for cooling system information Fan Control Bypass T...

Page 382: ...ested using an ohmmeter If the ECT circuit is open the engine Hot light and fan will both come on With the engine at an ambient temperature of 68 F 20 C disconnect lead and measure the resistance of s...

Page 383: ...sensor to touch the bottom of the water container Slowly heat the water to 190 F 88 C minimum Use the Temperature Resistance table to determine if the sensor needs to be replaced NOTE If the coolant t...

Page 384: ...e tension is lost the switch contacts close connecting the black wire to ground which prevents ignition spark This is the same as turning the key or engine stop switch OFF NOTE ETC will not activate u...

Page 385: ...elease the electrical charge collapsing the coil field for ignition based on the ECU timing map CDI A 12 volt DC current is supplied directly from the battery to the CDI At the CDI a DC current is sup...

Page 387: ...10 23 ELECTRICAL 10 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc EFI Ignition System Testing Flow Chart Crankshaft Position Sensor Gap...

Page 388: ...ester Re connect all wires Disconnect spark plug wire from the spark plug Connect gap tester lead to engine ground and the other to the ignition coil primary wire leading from the coil Crank engine an...

Page 389: ...art the engine With the engine running at idle observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the battery starts to charge ammeter indication i...

Page 390: ...re AC Voltage Output of Each Stator Leg at Charging RPM 1 Set the selector dial to measure AC Voltage 2 Start the engine and let it idle 3 While holding the ATV at a specified RPM separately measure t...

Page 391: ...2011 Polaris Sales Inc Charging System Testing Diagrams Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condition co...

Page 393: ...an 12 Vdc supply switched on by the ECU enables power to fan R B 12 Vdc to fan switch ECU RELAY COLOR FUNCTION Red White KEY ON Battery power supply switched on by the key and LH control switches enab...

Page 394: ...arate 10 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 clus...

Page 395: ...s 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 Discon...

Page 396: ...urn knob clockwise 1 Place the vehicle on a level surface with 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...

Page 397: ...he life of the lamp 4 Install the harness assembly into the headlight assembly Turn the headlight harness clockwise to secure the headlamp into place Lower Headlamp Housing Removal if required 5 Remov...

Page 398: ...ole in the center of the boss as indicated below to access the upper mounting adjustment screw 4 Adjust the beam to the desired position by loosening or tightening the 3 T 25 adjustment mounting screw...

Page 399: ...manual for the correct bulb part number Brake Light Switch 1 Disconnect battery 2 Remove the front rack 3 Remove the front cover 4 Locate and remove both relays from the relay block Remove single Torx...

Page 400: ...ce 3 Hook up an ohm meter to the fuel sender harness wire B and wire C 4 With the sender float in the empty position the meter should read 5 ohms 5 Slowly tilt invert the tank so that gravity moves th...

Page 401: ...charged Low specific gravity Loose or faulty battery cables or corroded connections see Voltage Drop Tests Related wiring loose disconnected or corroded Poor ground connections at battery cable starte...

Page 402: ...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...

Page 403: ...39 ELECTRICAL 10 9923412 2012 Sportsman 400 500 and EFI Tractor Service Manual Copyright 2011 Polaris Sales Inc Starter Lockout Diagram EFI Starter Lockout Diagram Carb Internal Harness Non Serviceab...

Page 404: ...gether 4 Remove the shims from the armature shaft and inspect the O rings located on the armature housing NOTE The shims must be reinstalled during reassembly Brush Inspection Replacement 1 Measure re...

Page 405: ...inal bolt to prevent O Ring damage during reinstallation 3 Install the O Ring over the bolt Make sure the O ring is fully seated 4 Remove the electrical tape and reinstall the two small phenolic washe...

Page 406: ...of field magnet casing Make sure it is in good condition and not twisted on the case 5 Align casing marks and install housing pushing back brushes while installing shaft in bushing 6 Reinstall starter...

Page 407: ...ff the end of the shaft Slide the new spring over 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...

Page 408: ...h must be on Replace component if failed Test starter solenoid coil by connecting an ohmmeter between the solenoid wire and the solenoid mounting plate Check solenoid ground path by measuring resistan...

Page 409: ...he correct service and charging procedures that follow in the manual Battery Conductance Analyzer Conductance describes the ability of a battery to conduct current A conductance tester functions by se...

Page 410: ...ch has a reading of 1 270 or higher Battery Terminals Bolts Terminal Preparation Use Polaris corrosion resistant Nyogel grease PN 2871329 on battery bolts and terminals when installing a battery This...

Page 411: ...ry cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cab...

Page 412: ...can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in...

Page 413: ...s freezing points by specific gravity Charging Procedure 1 Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging 2 Charge the battery with a charging output no...

Page 414: ...the battery acid to be fully absorbed For this reason a Low Maintenance battery case is dark and the cell caps are not removable since there is no need to check electrolyte level NEVER attempt to add...

Page 415: ...moved using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cables correctly 3 Reinstall battery attaching positive red cable firs...

Page 416: ...orking properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrica...

Page 417: ...Load Test Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning Using a wire brush or knif...

Page 420: ...t the flasher driver output to both left and right turn signal lights via two diodes While the ignition is on the flash driver will be toggling on and off regardless of turn or hazard switch position...

Page 421: ...ove the tail lamp electrical connector B press in on the tab on the connector to unlock the connector and pull the connector from the bulb assembly 3 To exchange either of the bulbs turn the housing 1...

Page 422: ...bly you wish to replace 3 Press the retainer tabs using your fingers or a pliers and push the assembly out of the housing 4 Insert a new assembly intothe corresponding opening and install the harness...

Page 423: ...GN FUEL Relay When the speed sensor signal rises over 40 Kph 25 Mph the ECU triggers the solenoid valve to open allowing atmospheric pressure on top of the air control body diaphragm which limits the...

Page 424: ...NOTES ELECTRICAL 10 60...

Page 425: ...Located By Battery...

Page 426: ......

Page 427: ...Located By Transmission Breakout Resistor Module...

Page 428: ......

Page 429: ...Located By Battery...

Page 430: ......

Page 431: ...Located By Transmission Breakout Resistor Module...

Page 432: ......

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Polaris 2012 Sportsman Forest 500 International, Service Manual

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Summary of Contents for 2012 Sportsman Forest 500 International

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