Polaris A09BA50FA User Manual Download Page 192 | Manualshive

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TRANSMISSION

8.8

TROUBLESHOOTING
CHECKLIST

Check the following items when shifting difficulty is
encountered.

S

Idle speed adjustment

S

Transmission oil type/quality

S

Transmission

torque

stop

adjustment

S

Engine torque stop adjustment

S

Drive belt deflection

S

Loose fasteners on rod ends

S

Loose fasteners on shifter

S

Worn rod ends, clevis pins, or pivot
arm bushings

S

Linkage rod adjustment and rod end
positioning

S

*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 rods from
transmission bellcranks. Manually select each gear
range at the transmission bellcrank, and test ride
vehicle. If it functions properly, the problem is outside
the transmission.

If

transmission

problem

remains,

disassemble

transmission and inspect all gear dogs for wear
(rounding), damage. Inspect all bearings for wear.

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Summary of Contents for A09BA50FA

Page 1: ...umber Location 1 2 Replacement Keys 1 3 Publication Numbers 1 3 Paint Codes 1 3 Specifications 1 4 1 5 Standard Torque Specifications 1 6 Tap Drill Charts 1 7 Decimal Equivalent Chart 1 7 Unit of Meas...

Page 2: ...No Body Style Check Digit World Mfg ID This could be either a number or a letter 9 ENGINE SERIAL NUMBER LOCATION Whenever corresponding about a vehicle be sure to refer to the engine model number and...

Page 3: ...78 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 PUBLICATION NUMBERS Year Model Model No Owner s Manual Parts Manual 2009 Scrambler 500 4x4 A09BG50...

Page 4: ...ity Length 75 in 190 5 cm Width 46 in 116 8 cm Height 47 in 119 4 cm Wheel Base 48 in 121 9 cm Dry Weight 571 lbs 259 kg 4x4 571 lbs 259 kg 2x4 Gross Vehicle Weight 845 Lbs 383 kg 4x4 845 Lbs 383 kg 2...

Page 5: ...ance 14 Amp Hr Circuit Breakers Solid State in PDM Starting Electric Drivetrain Transmission Type H N Rev Transmission Capacity 32 oz 945ml Front AWD Hub Capacity 2 5 oz 75ml Front Gearcase Capacity 4...

Page 6: ...ine sections Bolt Size Threads In Grade 2 Grade 5 Grade 8 Torque in lbs Nm 10 24 27 3 1 43 5 0 60 6 9 10 32 31 3 6 49 5 6 68 7 8 Torque ft lbs Nm 1 4 20 5 7 8 11 12 16 1 4 28 6 8 10 14 14 19 5 16 18 1...

Page 7: ...11 32 R 3 8 13 32 13 32 0 0995 0 0937 0 1285 0 125 0 166 0 161 0 196 0 234 0 277 0 265 0 3125 0 3125 0 3437 0 339 0 375 0 406 0 406 3 32 3 32 1 8 1 8 11 64 5 32 13 64 15 64 9 32 17 64 5 16 5 16 11 32...

Page 8: ...ubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp...

Page 9: ...cator while crankshaft is supported between centers on V blocks or resting in crankcase Measure at various points especially at PTO DCV Direct current voltage Dial Bore Gauge A cylinder measuring inst...

Page 10: ...reases Reservoir Tank The fill tank in the liquid cooling system Resistance Inthemechanical sense frictionor load Inthe electrical sense ohms Bothresult inenergy conversionto heat Right Side Always re...

Page 11: ...16 2 17 Fuel System 2 17 2 18 Compression Test 2 19 Battery Maintenance 2 19 2 21 Electrical 2 21 2 22 Coolant System Maintenance 2 23 Air Filter Service 2 24 2 25 Air Box Sediment Tube Service 2 25...

Page 12: ...il level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key The following symbols denote potential items...

Page 13: ...rs Headlamp tail lamp Daily Check operation apply dielectric grease if re placing E Air filter main element Weekly Inspect replace as needed Recoil housing Weekly Drain water as needed check often if...

Page 14: ...ttle Cable ETC Switch 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary J E Choke cable 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange...

Page 15: ...ect replace as needed J E Ignition Timing 100 H 12 M 620 1000 Inspect Wiring 100 H 12 M 620 1000 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc J Cl...

Page 16: ...ant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count NOTE Each item can be purchased separately at your local Polaris dealer Part No Description Additives Sealants Thread Locking Agents Misc 287427...

Page 17: ...peration G Headlight Taillight Brakelight check operation of all indicator lights and switches G Engine stop switch check for proper function G Wheels check for loose wheel nuts G Air cleaner element...

Page 18: ...LUIDS FOR SCRAMBLER 500 MODELS Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer 2873554 ATV Oil Change Kit Oil Filter 3 Qts of 0W 40 oil Reservoir Gasket Drai...

Page 19: ...Approx 32 oz Change annually 3 Brake Fluid Polaris DOT 3 Brake Fluid Fill master cylinder reservoir to in dicated level inside reservoir As required Change fluid every 2 years 4 Drive Chain Polaris C...

Page 20: ...e Semi annually 8 Propshaft Yoke Premium U Joint Grease Locate fittings and grease 3 pumps maximum Annually 9 Swing Arm Bush ings Polaris All Season Grease Locate grease fitting on swing arm and greas...

Page 21: ...nt to use is ATV Angle Drive Fluid PN 2871653 or an equivalent lubricant with a GL5 rating Fill plug Make sure vent is unobstructed Drain plug ADF Specified Lubricant ATV Angle Drive Fluid PN 2871653...

Page 22: ...s To check the level 1 Remove propshaft shield from the right side of the vehicle 2 Remove fill plug and visually inspect the oil level Level is correct when it reaches the bottom of the fill hole as...

Page 23: ...age rod between 1 8 and 1 4 turn after both jam nuts are tight G The transmission shift linkage should be periodically inspected for wear and parts replaced as required to remove excess play from shif...

Page 24: ...properly and in good condition repeat adjustment procedure 5 Replace the throttle cable if worn kinked or damaged PILOT SCREW The pilot system supplies fuel during engine operation with the throttle v...

Page 25: ...00DX or the PET 2500 PN 8712500 4 Set idle speed to 1200 RPM Always check throttle cable freeplay after adjusting idle speed and adjust if necessary 5 Slowly turn mixture screw clockwise using the pil...

Page 26: ...full right with transmission in neutral Engine RPM should not change and the engine should not die If either of these occur return to the first step THROTTLE OPERATION To remove the ETC cover 1 Use a...

Page 27: ...sparks in or near the area where refueling is performed or where gasoline is stored G Do not overfill the tank Do not fill the tank neck G If you get gasoline in your eyes or if you swallow gasoline s...

Page 28: ...ed Close To Carburetor 5 Install clamps on fuel line 6 Turn fuel valve ON 7 Start engine and inspect for leaks CARBURETOR DRAINING The carburetor float bowl should be drained periodically to remove mo...

Page 29: ...ASTENER TORQUE Check engine fasteners and ensure they are tight BATTERY MAINTENANCE WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin e...

Page 30: ...ow Maintenance batteries To service a Low Maintenance battery 1 Remove battery from the vehicle 2 Test battery with a voltage meter or load tester to determine battery condition This will determine th...

Page 31: ...oon baking soda Rinse well with clean water and dry thoroughly 5 Reinstall battery attaching positive red cable first and then the negative black cable 6 Coat terminals and bolt threads with Dielectri...

Page 32: ...ften during the break in period G Overheating of engine could occur if air is not fully purged from system G PolarisPremium60 40anti freezeis premixed and ready to use Do not dilute with water COOLANT...

Page 33: ...to upper mark with Polaris Premium 60 40 Anti Freeze Coolant PN 2871323 or a mixture of antifreeze and distilled water as required for freeze protection in your area 3 Reinstall cap NOTE If overheatin...

Page 34: ...he 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...

Page 35: ...ble in the clear tube Sediment Tube 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 1 Remove dr...

Page 36: ...y by removing the recoil G Do not open the crankcase drain unless the engine has ingested water Some engine oil will be lost if crankcase drain is opened G If recoil handle seal has been damaged the h...

Page 37: ...tainers before opening any compartment or disassembly any component containing fluids 1 Place vehicle on a level surface 2 Run engine two to three minutes until warm Stop engine 3 Clean area around dr...

Page 38: ...4 21 Place gear selector in Park and set parking brake NOTE Clamp or pinch off the vent line 2 from the oil tank as shown below in the Oil Pump Priming Procedure for the 500 engine 22 Re check the oil...

Page 39: ...lightly with a soft faced hammer to loosen it from the cylinder head 5 Remove timing inspection plug from recoil housing CAUTION Failure to position the crankshaft at TDC on compression stroke will r...

Page 40: ...ect with locknut secured STEERING The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Also check to make sure all cotter pins are in place If cotter...

Page 41: ...information CAMBER AND CASTER The camber and caster are non adjustable WHEEL ALIGNMENT METHOD 1 STRAIGHTEDGE OR STRING Be sure to keep handlebars centered See notes below NOTE String should just touc...

Page 42: ...ncorrect 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...

Page 43: ...Do not stand behind or in front of the ve hicle while purging the carbon from the spark arrestor G Never run the engine in an enclosed area Exhaust contains poisonous car bon monoxide gas G Do not go...

Page 44: ...ht Glass Min Max Rear Master Cylinder Reservoir G Check brake system for fluid leaks G Check brake for excessive travel or spongy feel G Check friction pads for wear damage or looseness G Check surfac...

Page 45: ...ean the chain as damage to the O Rings may occur Clean chain with hot soapy water and a soft bristled nylon brush Never allow battery acid to contact the drive chain Service Limit 1 4 6mm Drive Chain...

Page 46: ...ously been on the under part of the chain is now on the top side of the chain The bottom part of the chain should be taught during inspection Measure the chain deflection as shown in the diagram Defle...

Page 47: ...alternate method if 2 1 2 wrench is not available Tighten Loosen 5 Insert a pin punch through the sprocket hub and into the eccentric axle housing Alternate Adjustment Method Pin Punch Step 5 and 6 6...

Page 48: ...e applicable Reposition chain guide to allow 1 8 3 cm clearance between sprocket and guide Chain Guide SUSPENSION SPRING PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspensionspringp...

Page 49: ...ge Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts WHEEL HUB AND SPINDLE TORQUE TABLE Item Specification Front Wheel Nuts 27 Ft Lbs 27 Nm Rear Wheel Nuts 50 Ft Lbs 68 Nm...

Page 50: ...3 TIRE INSPECTION CAUTION G Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle G Improper tire inflation may affect ATV maneuverability G When replacing a t...

Page 51: ...H50PL Engine Oil Flow charts 3 12 EH50PL Engine Exploded Views 3 13 EH50PL Engine Top End Disassembly 3 14 3 23 EH50PL Valve Seat Service 3 23 3 26 EH50PL Cylinder Head Assembly 3 26 3 27 EH50PL Cylin...

Page 52: ...embly 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 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm Oil Filter Pipe Fitting 20...

Page 53: ...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 y Standard height 3 870 98 3 mm Valve Seat Contacting width In Std 028...

Page 54: ...sh by hand fit at 68 F 20 C Piston Ring Piston ring installed Top Std 0079 0138 20 36 mm g g gap p ring Limit 039 1 0 mm Second Std 0079 0138 20 36 mm ring Limit 039 1 0 mm Oil ring Std 0079 0276 20 7...

Page 55: ...ve an identification mark the direction for placement of the piston does not matter Note the directional and identification marks when viewing the pistons from the top The letter F or must always be t...

Page 56: ...r 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...

Page 57: ...ature Hot Light On 178 190 215 F 102 C Fan Off 296 316 180 F 82 C Fan On 236 251 195 F 91 C System Capacity 2 25 Quarts 2 13L Radiator Cap Relief Pressure 13 PSI RECOMMENDED COOLANT Use only high qual...

Page 58: ...and remove chain and sprockets as an assembly 13 Refer to PVT System to remove outer clutch cover drive belt drive clutch driven clutch and inner cover 14 Starter motor Note ground cable location Mark...

Page 59: ...ning oil and a coarse roughing stone Measure the piston see piston measurement and rough hone to the size of the piston Always leave 002 003 05 07 mm for finish honing Refer to piston to cylinder clea...

Page 60: ...own in the illustration at right squeeze the crankshaft at point A Use tool from alignment kit A HIGH 002 05mm HIGH 005 13mm A 3 If the crank rod pin location is 180_ from the dial indicator opposite...

Page 61: ...the filter element At this point the oil is diverted in two directions Oil is supplied to the camshaft through the left front cylinder stud and an oil passage in the head Oil enters the camshaft thro...

Page 62: ...kcase Small End Bearing Cylinder Sleeve Main Bearing PTO Large End Bearing Crank Pin Crankshaft Screen Fitting Bottom of Tank EH50PL Oil Flow Chart Top of Oil Tank Union Fitting Lower Oil Jet Union Fi...

Page 63: ...ENGINE 3 13 EH50PL ENGINE EXPLODED VIEW Crankcase Cylinder Cylinder Head Crankshaft and Piston Valve Train A...

Page 64: ...engine slowly watching camshaft sprocket marks and the mark in the timing inspection hole 4 Align single TDC mark on flywheel with projection in inspection hole and the cam sprocket pin facing upward...

Page 65: ...Spring Free Length 2 02I 5 13 cm 4 Measure free length of tensioner spring Replace spring if excessively worn Compare to specifications 5 Replace entire tensioner assembly if any part is worn or dama...

Page 66: ...rts and visually inspect surface Compare to specifications 6 Subtract rocker shaft O D from rocker arm shaft support I D This is the oil clearance Compare to specifications 7 Inspect rocker adjuster s...

Page 67: ...e to prevent it from falling into the crankcase Inspect for Areas of Tooth Wear or Damage Sprocket Teeth 9 Inspect cam sprocket teeth for wear or damage Replace if necessary Decompressor Ball Retainer...

Page 68: ...and install the release lever shaft If Camshaft Is Installed In The Engine 4 Use a small magnet to draw the actuator ball outward or rotate the engine until the cam lobes face upward and install rele...

Page 69: ...I 055 090 mm Limit 0039I 10 mm NOTE Replace camshaft if damaged or if any part is worn past the service limit NOTE Replace cylinder head if camshaft journal bore is damaged or worn excessively CYLINDE...

Page 70: ...ENGINE 3 20 CYLINDER HEAD EXPLODED VIEW EH50PL EH50PL...

Page 71: ...DER HEAD DISASSEMBLY WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly NOTE Keep all parts in order with respect to their location in the cylinder head A 1 U...

Page 72: ...check for bent valve stems mount valve in a drill or use V blocks and a dial indicator A B 3 Check end of valve stem for flaring pitting wear or damage A 4 Inspect split keeper groove for wear or fla...

Page 73: ...g the valve guides and valve seats requires special tools and a thorough knowledge of reconditioning techniques Follow the instructions provided in the cylinder head service tool kit CAUTION Wear eye...

Page 74: ...lled Height Valve Guide Height 689 709I 17 5 18 0 mm 4 Place a new guide in the valve guide installation tool and press guide in to proper depth Check height of each guide above the cylinder head A NO...

Page 75: ...r 75 cutter to raise the seat When contact area is centered on the valve face measure seat width S If the seat is too wide or uneven use both top and bottom cutters to narrow the seat S If the seat is...

Page 76: ...carefully with a rotating motion to avoid damaging valve seal 5 Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head 6 Place retaine...

Page 77: ...engine valves NOTE Both feeler gauges should remain inserted during adjustment of each valve 006 15 mm EXHAUST VALVE CLEARANCE 3 When clearance is correct hold adjuster screw and tighten locknut secu...

Page 78: ...ed areas only until loose 7 Rock cylinder forward and backward and lift it from the crankcase supporting piston and connecting rod Support piston with Piston Support Block PN 2870390 8 Remove dowel pi...

Page 79: ...first followed by the bottom rail 6 Remove the expander CYLINDER INSPECTION 1 Remove all gasket material from the cylinder sealing surfaces 2 Inspect the top of the cylinder for warpage using a straig...

Page 80: ...n Bore Piston Pin Bore 9055 9057I 23 0 23 006 mm 1 Measure piston pin bore Piston Pin Measurement Locations Piston Pin O D 9053 9055I 22 994 23 0 mm 2 Measure piston pin O D Replace piston and or pist...

Page 81: ...cified 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 an...

Page 82: ...heel nut and washer 2 Install Flywheel Puller PN 2871043 and remove flywheel CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 3 Mark or note positi...

Page 83: ...sher B spring C and one way valve D from PTO side crankcase 2 Inspect free length of spring and check coils for distortion One Way Valve Spring Free Length Std 1 450 3 68 cm 3 Inspect valve for wear 4...

Page 84: ...gear C 3 Inspect drive gear teeth for cracks damage or excessive wear 4 Remove three oil pump retaining bolts and pump 5 Inspect mating surface of crankcase and oil pump Check for nicks burrs or surfa...

Page 85: ...or wear OIL PUMP ASSEMBLY 1 Clean and dry all parts thoroughly Apply clean engine oil to all parts Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged 2 Insta...

Page 86: ...galling Turn the inner race of each bearing The bearings should turn smoothly and quietly The outer race of each bearing should fit tightly in the crankcase The inner race should be firm with minimal...

Page 87: ...bearings and pump shaft bearing use a blind hole bearing puller NOTE Bearings are stressed during the removal process and should not be re used PUMP SHAFT OIL SEAL WATER PUMP MECHANICAL SEAL REMOVAL E...

Page 88: ...INSPECTION ADJUSTMENT Before reassembling the crankcase the following steps should be performed to determine the amount of crankshaft counter balancer shaft and pump shaft end play Excessive end play...

Page 89: ...record below Total Case Width 7 Measure the width of the crankshaft at the bearing seats with a micrometer or dial caliper and record Crankshaft Width 8 Subtract the Crankshaft Width measured in Step...

Page 90: ...red in Step 2 from the figure obtained in Step 5 7 Subtract the thickness of the existing shim from the result of Step 6 to determine if a different shim is needed The result must be within the specif...

Page 91: ...ace the balancer shaft in the PTO crankcase aligning the timing marks on the crankshaft and balancer gears Install the proper shim washer on the shaft 5 Inspect the oil pump sealing surface on the cra...

Page 92: ...careless use of this tool or procedure can result in a bent water pump shaft Pump shaft replacement requires engine removal and crankcase separation Use caution while performing this procedure Make s...

Page 93: ...nical seal has been removed from the cases Ill 6 Pump shaft oil seal can also be replaced at this time if necessary 7 The Water Pump Install Kit PN 5131135 is required to install the new mechanical se...

Page 94: ...on The tab must be positioned in the notch on the side of the piston as shown A A 3 Install the bottom rail with the gap at least 30 from the end of the expander on the side opposite the top rail gap...

Page 95: ...linder base gasket A 2 Position the Piston Support Block PN 2870390 A beneath the piston skirt to support the piston during cylinder installation 3 Apply clean engine oil to the ring compressor Snap O...

Page 96: ...reads and washers and hand tighten the bolts The following procedure must be used to torque the cylinder head properly Torque all bolts evenly in a criss cross pattern Torque bolts to 22 ft lbs 30 Nm...

Page 97: ...utward and the alignment pin notch facing directly upward A B 5 Before positioning the sprocket on the camshaft check the position of the cam sprocket alignment pin When the cam is positioned properly...

Page 98: ...ENGINE 3 48 CAMSHAFT TIMING Single TDC Mark Aligned Crankshaft to Camshaft Centerline Sprocket Alignment Pin Do Not Use Advance Marks Rotation TDC Mark Dots...

Page 99: ...the crankshaft seal Apply molybdenum disulfide grease or assembly lubricant to the crankshaft bushing 2 Install a new O Ring in the oil passage recess in the crankcase 3 Apply 3 Bond 1215 PN 2871557...

Page 100: ...faces 4 Rotate the engine until the cam lobes are pointing downward 5 Be sure the dowel pins are in place and install the rocker shaft assembly 6 Apply a light film of engine oil to the threads of the...

Page 101: ...llow water or dirt to enter the recoil housing through the rope NOTE The handle must seal tightly on the recoil housing to prevent water from entering 11 Remove center bolt from recoil friction plate...

Page 102: ...Season Grease PN 2871423 To complete 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...

Page 103: ...Low compression high cylinder leakage S No spark Spark plug fouled Engine Does Not Turn Over S Dead battery S Starter motor does not turn S Engine seized rusted or mechanical failure Engine Runs But W...

Page 104: ...sticking S Air leaks in intake S Lean condition COOLING SYSTEM TROUBLESHOOTING Overheating S Low coolant level S Air in cooling system S Wrong type of coolant S Faulty pressure cap or system leaks S R...

Page 105: ...CV Carburetor System Function 4 Cycle 4 6 CV Carburetor Vent System 4 Cycle 4 6 CV Carburetor Operation 4 6 4 8 Pilot Screw Information 4 9 Disassembly Notes CV Carburetor 4 8 4 9 Cleaning CV Carbure...

Page 106: ...6 Jet Needle 7 Diaphragm Assembly 8 Throttle Valve 9 Cable Guide 10 Spring 11 Adjuster Cable 12 Drain Plug 13 O Ring 14 Jet Main 15 Spacer Ring 16 Drain Screw 17 O Ring 18 Float Assembly 19 Plug 20 Pi...

Page 107: ...EM CARBURETION 4 3 FUEL TANK ASSEMBLY Forward Fuel tank mounted valve Fuel Tank Fuel Valve Engine Filter Fuel Pump Carburetor Fuel Tank Vent Carburetor Vent Fitting Screens L L Located Above Oil Tank...

Page 108: ...evere burns may result Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If you get gasoline in your eyes or if you should swallo...

Page 109: ...icipated temperature at which the machine will be operated 2 Determine the lowest approximate altitude at which the machine will be operated 3 Select the correct main jet from the chart on page 1 4 4...

Page 110: ...id range and high throttle settings 1 4 to full throttle VENT SYSTEMS CV CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl The lines must be free of kinks r...

Page 111: ...ikuni BST carburetor PILOT IDLE AND SLOW SYSTEM This system supplies fuel during engine operation with throttle valve closed 1 or slightly opened The fuel from float chamber 2 is metered by pilot jet...

Page 112: ...MAIN SYSTEM As throttle valve 1 is opened engine speed rises and this increases negative pressure in the venturi Consequently the vacuum slide 2 moves upward The fuel in float chamber 3 is metered by...

Page 113: ...eyes or if you swallow cleaner seek medical attention immediately Carburetor cleaners can be extremely caustic Extended periods of soaking can loosen the adhesive sealer on the passage drill way plug...

Page 114: ...Needle Jet 2 Inspect the inlet needle tapered surface for any sign of wear or damage Be sure the spring loaded pin is free moving and returns freely when pushed The inlet needle and seat should be pre...

Page 115: ...float arm In this position the float tongue will rest lightly on the inlet needle valve pin without compressing the spring Float Height Std BST 40 14 7mm 58 1 mm NOTE On BST 40 carburetors it is impor...

Page 116: ...ds and is sealed with a brass plug to prevent tampering Removal of the tamper proof plug is not permitted For service purposes cleaning of the pilot circuit can be done only by a certified repair shop...

Page 117: ...ragm is ruptured The pump diaphragms must be replaced Fuel Filter Fuel Pump Impulse line FUEL PUMP DISASSEMBLY 1 Remove the screws from the pump diaphragm cover Note the location of the two longer scr...

Page 118: ...XPLODED VIEW Fuel Pump Exploded View at Right 3 2 1 5 5 4 1 Fuel Pump Assembly 2 Diaphragm Gasket Set 3 Screw and Washer Assembly 4 Screw and Washer Assembly 5 Screw and Washer Assembly 6 Pressure Reg...

Page 119: ...Choke plunger sticking incorrectly adjusted choke G Choke cable binding or improperly routed G Incorrect pilot air fuel screw adjustment G Faulty inlet needle and seat G Faulty inlet needle seat O Ri...

Page 120: ...FUEL SYSTEM CARBURETION 4 16 NOTES...

Page 121: ...ly Exploded View 5 4 A Arm Replacement 5 5 Concentric Swing Arm Removal 5 6 Concentric Swing Arm Assembly Installation 5 7 Rear Swing Arm Weldment 5 7 5 8 Strut Assembly Exploded View 4x4 5 8 Strut As...

Page 122: ...ECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870871 Ball Joint Replacement Tool 2870872 Shock Spanner Wrench 2870623 Shock Absorber Spring Compression Tool 2871572 Strut Rod Wrench 2871573 LH Strut Sprin...

Page 123: ...BODY STEERING SUSPENSION 5 3 BODY ASSEMBLY EXPLODED VIEW Rear Cab Assembly Front Cab Assembly Seat Release Latch Mud Flap Front Cab Front Cover Panel or Headlight Cover Mud Flap...

Page 124: ...Arm Frog Left Hand Tie Rod End Positioned Below Steer ing Post Arms 1 2 Right Hand Tie Rod End Positioned Between Steering Post Arms NOTE To avoid damage to tie rods and other steering components be...

Page 125: ...ting bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 5 Examine A arm shaft Replace if worn Discard hardware 6 I...

Page 126: ...sassembly 1 Lift rear of machine and support securely with wheels off the floor 2 Remove drive chain 3 Remove rear caliper CAUTION Do not allow the caliper to hang by the brake line Brake line damage...

Page 127: ...lel with top surface of the swingarm 1 Install bushing 6 in left side of swingarm and two piece bushings 3 in right side 2 Clean threads of nut 1 and pivot bushings 4 3 Install right pivot bushing 4 t...

Page 128: ...ment will be necessary Grease fitting 2 location Check lubrication guide for recommended service intervals Specified pole gap is 0 001 0 0254mm 1 2 15 ft lbs 21 Nm Nut 15 ft lbs 21 Nm 18 ft lbs 25 Nm...

Page 129: ...LY 2X4 15 ft lbs 21 Nm Nut 15 ft lbs 20 Nm 40 ft lbs 54 Nm Cotter Pin Lower A Arm Pivot Washer Spring Retainer Spring Pinch Bolt Jam Nut Spring Retainer Strut Bumper 45 ft lbs 61 Nm Strut 14 ft lbs 19...

Page 130: ...re installed properly and seated fully 10 Torque strut rod nut to specification Do not over torque nut Strut Rod Nut Torque 15 ft lbs 21 Nm BALL JOINT REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5 8 1 L...

Page 131: ...kit G Insert new ball joint E into driver F F E G Slide ball joint driver assembly into guide G Drive new joint into strut housing until fully seated 9 Apply Loctitet 242 PN 2871949 to threads of ret...

Page 132: ...ic polyethylene material Therefore they must be flame treated prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the w...

Page 133: ...tions 6 8 Shift Weights 6 9 Drive Clutch Inspection 6 10 Drive Clutch Disassembly Inspection 6 11 6 12 Drive Clutch Assembly 6 12 6 13 Drive Belt Tension 6 13 Drive Belt Removal Inspection 6 14 6 15 D...

Page 134: ...ents of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the development of a Polaris ATV the PVT system is matched first to the engin...

Page 135: ...fset Belt Width See Page 6 16 6 18 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs See Pa...

Page 136: ...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...

Page 137: ...for drive belt removal A B 6 Install the Drive Clutch Holder PN 9314177 A 7 Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Holder PN 9314177 B Drive Clutch Puller PN...

Page 138: ...Rear 12 ft lbs 16 6 Nm Driven Clutch Retaining Bolt Torque 17 ft lbs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 ft lbs 55 Nm Offset Spacer Offset Spacer 7 Install clutch offset spacers on transmiss...

Page 139: ...CH EXPLODED VIEW Outer Cover Exhaust Duct Inner Cover Seal Inlet duct Inner Cover Outer Cover Seal Drive Clutch Mark with permanent marker before disassembly Teflont coated brass bushing Teflont coate...

Page 140: ...s subject to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from...

Page 141: ...agement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clea...

Page 142: ...learance exists replace all buttons and inspect surface of towers See SPIDER REMOVAL Page 6 11 Button to Tower Clearance 000 001I 2 Inspect sheave surfaces Replace the entire service clutch if worn da...

Page 143: ...ushing A The outer cover bushing is manufactured with a Teflont coating Bushing wear is determined by the amount of Teflont remaining on the bushing Inspect shaft 4 Inspect area on shaft where bushing...

Page 144: ...in Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 2 Rubber backed buttons can be used in all ATV clutches if t...

Page 145: ...on to avoid damage to the stationary sheave Refer to Page 6 2 for torque specification CAUTION Be sure the spider spacer washers are fully seated in the recessed area in the spider Any misalignment wi...

Page 146: ...ffect on belt deflection DRIVE BELT 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 directio...

Page 147: ...nominal length may require driven shimming or a shorter center distance Remember proper belt deflection is the desired goal not a specific center distance 8 Replace belt if worn past the service limit...

Page 148: ...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 remov...

Page 149: ...nto bench vise and lightly grease puller threads Piston Pin Puller PN 2870386 2 Remove nut from puller rod and set aside Piston Pin Puller PN 2870386 Main Puller Adaptor 8 3 Install the Main Puller Ad...

Page 150: ...to center of sheave and with towers pointing away from vise slide sheave onto puller rod 4 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 5 Turn sheave an...

Page 151: ...ushing PN 3576510 Loctitet 680 PN 2870584 2 With the Main Puller Adapter 8 PN 5020632 on the puller insert cover onto puller rod placing outside of cover toward vise 3 Install nut on rod and hand tigh...

Page 152: ...e sheaveand replace if worn NOTE The ramp buttons are secured by Torxt screws T20 Belt deflection adjustment washers 7 Remove moveable sheave and note the number of spacer washers One spacer must rema...

Page 153: ...er 1 or in Illustration 2 above The driven clutch helix moveable assembly has several different spring locations which affect clutch shifting and RPMs The greatest amount of spring tension will raise...

Page 154: ...5020632 onto the Piston Pin Puller PN 2870386 2 Insert Adapter Reducer 9 PN 5010279 onto the puller sliding it inside the main adapter 3 Remove ramp buttons from moveable sheave 4 Using an electric o...

Page 155: ...l from adapters Discard bushing DRIVEN CLUTCH MOVEABLE SHEAVE BUSHING INSTALLATION Number Two Puller Adapter 10 Piston Pin Puller PN 2870386 1 Working from the top insert Number Two Puller Adapter 10...

Page 156: ...urn clutch sheave counterclockwise until bushing is seated 6 Remove nut from puller rod and set aside 7 Remove installation tool and clutch sheave from puller 8 Repeat installation procedure for other...

Page 157: ...hts Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and insp...

Page 158: ...clutch engagement Caution operator to operate machine within guidelines Vehicle operated with park brake on Inspect brake system Fast effective use of throttle for efficient engagement PVT noise Belt...

Page 159: ...Front Drive Axle Installation 7 10 AWD Front CV Joint Boot Replace 7 10 7 12 AWD Front Drive Axle Exploded View 7 13 AWD Strut Casting Seal Replacement 7 13 AWD Strut Seal Sleeve Replacement 7 14 7 15...

Page 160: ...ture Plate Brake Disc Bearing Race Bearing 1 000 I D Garter Spring Spacer Cotter Pin Washer Wheel Nut Refer to text on page 7 5 for more information Detail Front Hub Clutch Bearing 1 000 I D Use new c...

Page 161: ...en the ramps and the ring in the hub See Ill 1 When the hub clutch assembly wheel hub and drive axle are engaged the front wheels will drive and stay engaged until rear wheel traction is regained When...

Page 162: ...iper and brake disc 3 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake hose Use wire to hang the caliper to prevent possible damage to the brake line 4 Place a...

Page 163: ...torque hub nut to 108 144 inch lbs 12 16 Nm Front Spindle Nut Torque 108 144 in lbs Brake Caliper Retaining Bolt Torque 18 ft lbs 25 Nm 5 Install cotter pin Bend each leg of cotter pin around castle n...

Page 164: ...sc mounting bolts to soften the locking agent 3 Apply heat to the hub seal area When the hub becomes too hot to touch pry out the old seal as shown Do not damage the surface of the seal cavity Clean t...

Page 165: ...ositioned a 1 16I 16 cm bead of silicone should remain around the inner edge Clean off all excess silicone The seal sleeve area must be free of silicone or the hub seal may leak NOTE S Always install...

Page 166: ...g These springs are very similar in appearance to those used on earlier models If the old lighter springs were installed on a machine requiring the heavier spring the front wheels may engage at high s...

Page 167: ...this service procedure Wear eye protection when removing and installing drive axles or component parts 3 Remove wheel nuts and wheels 4 Remove hub cap 5 Remove the two brake caliper attaching bolts C...

Page 168: ...or when servicing CV joints Driveshaft components are precision parts S Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life S The...

Page 169: ...indle and CV joint assembly from the axle shaft by pulling the shaft sharply outward away from the CV joint It may be necessary to tap the CV joint assembly outward with a soft faced hammer 7 Remove s...

Page 170: ...ion large end of boot on CV joint purge excess air by partially compressing axle into CV bell lift one edge of boot to let out excess air Secure with clamp Boot Replacement requires 30g Boot replaceme...

Page 171: ...Joint Assy Yoke Front Drive Axle Components Front Prop Shaft Components O Ring Yoke Propshaft to Transmission Prop Shaft Cross and Bearing Kit Spring Pin Yoke Front Gearcase Propshaft Assembly FINAL...

Page 172: ...in hole does not align at the above torque tighten slightly until the cotter pin hole aligns and install the pin with open ends toward rear of machine BEARING REPLACEMENT NOTE FOR FRONT DRIVE AXLE AND...

Page 173: ...edge on the outer pole so that it just intersects with the inner pole The gap between the straight edge and inner pole should be 0 to 001I 0 025mm This measurement should be checked in three differen...

Page 174: ...face hammer 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing caps 4 Force U joint cross to one side and lift out of inner yoke U JOINT ASSEMBLY 1 Install new b...

Page 175: ...ctions AWD FRONT HOUSING REMOVAL 1 Stop engine place machine in gear and set parking brake 2 Loosen right front wheel nuts slightly 3 Elevate and support machine under footrest frame area CAUTION Seri...

Page 176: ...plug unless it is backed out AWD FRONT HOUSING ASSEMBLY 1 Replace all O rings seals and worn components Bushings 2 Press pinion shaft seal into pinion cover until flush with sealing surface 3 Inspect...

Page 177: ...shaft assembly Equal Shims NOTE The same shim thickness placed behind ring gear bearing must also be put behind the cover button 7 Install output shaft cover with new o ring and torque bolts to 14 ft...

Page 178: ...FINAL DRIVE 7 20 AWD Front Housing Exploded View Pinion Cover Seal O Ring Bearing Pinion Shaft Output Shaft Bearing Shim O Ring Output Cover Thrust Button Shim Seal Vent Bushing Seal Retaining Ring...

Page 179: ...of the swingarm under the chain Remove the Splice link Clip Opening Position 4 Loosen the concentric clamp bolts 5 Remove the two bolts that secure the brake caliper Support the rear caliper with wire...

Page 180: ...xle D E F 11 Remove the O rings from left side of the axle 12 Slide the axle out the right side of the axle housing CONCENTRIC SWINGARM REAR AXLE ASSEMBLY INSTALLATION 1 Apply Never Seize onto the spl...

Page 181: ...le nut outward with a 1 3 4 Wrench PN 2870772 until the end of the axle nut G just covers the retaining ring H The retaining ring should still be visible under the axle nut from an angle Torque to 8 1...

Page 182: ...J K 80 ft lbs M 14 Install the rear wheels and torque wheel nuts to 50 ft lbs 68 Nm Rear Wheel Rear Wheel Nuts 4 50 ft lbs 68 Nm Rear Hub Nut 80 ft lbs 108 Nm Taper end faces wheel for install 15 Lubr...

Page 183: ...RING SERVICE 1 Drive in new bearing race with brass drift making sure that race fully seats in the housing 2 Lubricate and install new tapered bearings 3 Lubricate and install new seals CONCENTRIC SWI...

Page 184: ...Axle 4 3 Nut Nylok 5 1 Disc Brake 6 1 Hub Brake Disc 7 3 Screw 8 1 Ring Retaining 9 2 O Ring 10 2 Seal 11 2 Bearing Cone Tapered 12 2 Bearing Cup Tapered 13 1 Housing Axle Rear 14 1 Fitting Lubricati...

Page 185: ...TRANSMISSION 8 1 Torque Specifications 8 2 Transmission Removal Installation 8 2 Transmission Exploded View 8 3 Transmission Disassembly 8 3 8 6 Transmission Reassembly 8 6 8 7 Troubleshooting 8 8...

Page 186: ...T outer cover both drive and driven clutch and inner PVT cover refer to Clutch Chapter 6 4 Remove rear PVT bracket 5 Remove pin from front prop shaft at front housing Position U joint to allow pin to...

Page 187: ...h damage will occur if not removed prior to disassembly 2 Place bellcrank in neutral position 3 Remove sprocket retaining clip and sprocket 4 Remove the transmission cover bolts 5 With a soft face ham...

Page 188: ...ight on a flat surface and measure the length of 8 pitches in a minimum of three places on chain Replace chain if measurement is longer than 5 05I 128 27 mm Measure 8 pitches Chain Stretch Limit 8 pit...

Page 189: ...ment dog 13 Inspect input shaft gear and bearing Replace if necessary 14 Remove front output shaft cover and ring gear assembly 15 Remove ring gear and bearing from output shaft by standing assembly o...

Page 190: ...inspect for wear 24 Inspect engagement dogs of gears and replace if edges are rounded 25 Inspect gear teeth for wear cracks chips or broken teeth 26 Remove seals from transmission case NOTE New seals...

Page 191: ...the High Reverse shift arm must be placed in the neutral position to complete reassembly 9 Install output shaft and gear assembly along with sprocket and chain 10 Install snap ring 11 Prior to reinst...

Page 192: ...nkage rod adjustment and rod end positioning S Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem...

Page 193: ...11 Brake Burnishing 9 11 Front Disc Inspection 9 11 Front Disc Removal Replacement 9 11 9 12 Front Caliper Removal 9 12 Front Caliper Disassembly 9 12 9 13 Front Caliper Inspection 9 13 Front Caliper...

Page 194: ...3 810 4 166mm 140 3 556mm Brake Disc Thickness Variance Between Measurements 002 051mm Brake Disc Runout 005 25mm Master Cylinder I D Front 750 Master Cylinder I D Aux Rear 500 TORQUE SPECIFICATIONS I...

Page 195: ...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...

Page 196: ...freely and completely G Adjust stop pin on front caliper after pad service G Check and adjust master cylinder reservoir fluid level after pad service G Make sure atmospheric vent on reservoir is unob...

Page 197: ...n The caliper pistons are T shaped which allows both hand and foot brakes to use the same caliper piston but remain separated by seals The hand brake system applies hydraulic pressure to both front ca...

Page 198: ...nd place the other end in a clean container 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 Illustratio...

Page 199: ...e proper hole in the master cylinder Wiggle and press down on the cap to be sure if fits evenly and snug Torque the screw on the handle side first then torque other screw to 5 in lbs 0 56 Nm NOTE Be s...

Page 200: ...r the different Polaris ATV models Refer to your parts manual or guide for the correct parts The master cylinder is not serviceable and is replaced as a unit 1 Install master cylinder on handlebars To...

Page 201: ...not tip or fall Severe injury may occur if machine tips or falls 2 Remove the front wheel Loosen pad adjuster screw 2 3 turns 3 Remove caliper mounting bolts 4 Push caliper piston into caliper bore sl...

Page 202: ...s mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other Be sure pads and disc are free of dirt or grease 3 Install caliper on hub strut and t...

Page 203: ...e brake disc for nicks scratches or damage 2 Measure the disc thickness at eight different points around the pad contact surface using a 0 1 micrometer Replace disc if worn beyond service limit Brake...

Page 204: ...g vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 1 Remove brake pads See Page 9 33 2 Use a 1 2 wrench loosen and remove brake line to caliper Place a containe...

Page 205: ...place if damage is evident or if worn beyond service limit Front Caliper Piston Bore I D Std 1 191 1 192 30 25 30 28 mm Service Limit 1 193 30 30 mm 2 Inspect piston for nicks scratches wear or damage...

Page 206: ...e disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease FRONT CALIPER INSTALLATION 1 Install caliper on hub strut and torque mounting bolts 18 ft lbs 25 Nm 15 ft...

Page 207: ...LARIS DOT 3 BRAKE FLUID TO COMPONENT 3 3 3 35 60 IN LBS 4 6 5 NM 3 9 8 10 6 4 5 1 Caliper Mount 2 Brake Pads 3 Piston 4 Brake Caliper Body 5 Boot Seal 6 Pin Bushing Seal 7 O rings 8 Banjo Bolt 9 Bleed...

Page 208: ...installed press the piston into the caliper body NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess f...

Page 209: ...e fluid in the reservoir to prevent air from entering the master cylinder 7 It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and r...

Page 210: ...olts 4 Remove the slide bolt snap rings A the slide pins B the bracket pad C and the brake pads D A Caliper B C D 5 Remove the anvil bolts and separate caliper halves and remove pistons with piston pl...

Page 211: ...to ease assembly until fully seated O Rings Seals 2 Carefully assemble caliper body making sure O rings are properly positioned in groove Tighten the caliper anvil bolts and then torque the anvil bolt...

Page 212: ...not dragging when lever is released If the brake drags re check assembly and installation REAR BRAKE DISC INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace the disc if any de...

Page 213: ...30 35 ft lbs 41 47 Nm 25 30 in lbs 3 3 50 Nm 1 8 1 7 1 0 Item Torque Specification 3 3 3 1 Snap Ring 2 Outboard Anvil Body 3 Slide Pin Bushing 4 Brake Pad 5 Caliper Bracket 6 Dust Boot 7 Dust Boot 8 P...

Page 214: ...from the master cylinder Use a suitable container to catch the brake fluid Dispose of brake fluid properly 2 Remove the two bolts that secure the rear master cylinder to the brake mount plate Replace...

Page 215: ...ed lever S Incorrectly adjusted stationary pad S Worn or damaged master cylinder or components S Improper clearance between lever and switch Lever Vibration S Disc damaged S Disc worn runout or thickn...

Page 216: ...BRAKES 9 24 NOTES...

Page 217: ...est 10 11 Ignition System Troubleshooting 10 12 DC CDI Ignition System Testing 10 13 10 14 Cranking Output Test 10 15 Trans Gear Position Switch Test 10 15 Reverse Limiter Wiring Diagram 10 16 Reverse...

Page 218: ...Coil Meter NOTE CDI boxes may look the same but have different internal circuitry Be sure to always use the correct CDI box part number Battery Charging Coils 10 5k Pulse Coil Trigger Air Gap 016 030...

Page 219: ...used for when diagnosing electrical problems Readings obtained with other meters may differ GPay attention to the prefix on the multimeter reading K M etc and the position of the decimal point GFor re...

Page 220: ...regulator Solid state circuit breaker output Starter Lockout output and Engine temperature controller There are no service parts in the PDM If the PDM fails it must be replaced Following are overviews...

Page 221: ...ected during ON state only If the FAN output is open circuit upon power up the engine temperature controller will activate the hot indicator If the engine temperature exceeds the engine hot thermistor...

Page 222: ...mp J1 E THERM_RTN Thermistor ground J1 F THERM Thermistor input J1 G TRANS Transmission signal voltage input for starter lockout J1 H LIGHTS Powers vehicle lighting J1 J COIL 3 Alternator coil input J...

Page 223: ...T_PROT OUTPUT Output Current 8 Amp Nominal Continuous output current Limit 9 11 20 Amp Current level that will cause turn off after delay Time Delay 100 150 mSec Time above limit until SSCB trips Volt...

Page 224: ...RATURE CONTROLLER Open Thermistor Resistance 50k ohm Above this resistance is assumed to be an open thermistor causing the FAN and HOT indicator to activate Fan OFF Resistance 3362 3466 3570 ohm Therm...

Page 225: ...o come on HOT LIGHT CIRCUIT TEST 1 Disconnect the thermistor 2 Turn key and auxiliary switch to ON position The hot lamp and fan should come on Check the bulb and related wiring if the lamp does not i...

Page 226: ...e coolant temperature Should the thermistor fail open the engine Hot light and fan will both come on With engine cold disconnect lead and measure resistance of sensor between the two Yellow Black conn...

Page 227: ...me as turning the key or engine stop switch OFF Test the ETC switch at the harness connector NOTE Adjust throttle cable freeplay ETC switch and make sure throttle mechanism is functioning properly bef...

Page 228: ...ions wet corroded GPoor ignition coil ground e g coil mount loose or corroded GFaulty stator measure resistance of all ignition related windings GIncorrect wiring inspect color coding in connectors et...

Page 229: ...battery power for ignition Instead of generating DC voltage via magnetic induction a 12 volt DC current is supplied directly to the CDI unit from the battery At the CDI 12 volt DC current charges an i...

Page 230: ...mount using an ohmmeter The coil should have good continuity to ground on the engine 0 2 Replace Spark Plug Disconnect and check the secondary coil Resis tance values should be Primary Side Primary Wi...

Page 231: ...CDI OUTPUT TEST USING PEAK READING ADAPTOR Re connect all CDI wires Disconnect CDI module wire from ignition coil primary terminal Connect one meter lead to engine ground and the other to the ignition...

Page 232: ...Reverse Limit System Scrambler PDM To PDM To RD WH Splice To BN Splice To PDM To PDM To AWD Switch To ETC Switch From Hub Coil To Ignition Coil To RD WH Splice ELECTRICAL 10 16 REVERSE LIMIT SYSTEM...

Page 233: ...HY 1 FAULTY OVERRIDE SWITCH 2 WIRING CONNECTIONS NO YES MEASURE DC VOLTS Y R WIRE TO GROUND TO LR MODULE WITH EN GINE RUNNING AT IDLE RPM YES 3 9 VOLTS AC FIND WHY 1 WIRING CONNECTIONS 2 FAULTY CDI NO...

Page 234: ...EL COIL 6 WIRING CONNECTIONS 7 MECHANICAL AWD FAULT YES MEASURE DC VOLTS BRN WHT WIRE TO GROUND AT LR MODULE 12 VOLTS DC FIND WHY NO 1 FAULTY WHEEL COIL 2 WIRING CONNECTIONS 3 MECHANICAL AWD FAULT YES...

Page 235: ...R 3 FAULTY IGNITION SWITCH 4 FAULTY OFF RUN SWITCH 5 FAULTY WHEEL COIL 6 WIRING CONNECTIONS 7 MECHANICAL AWD FAULT YES MEASURE CONTINU ITY TO GROUND AT LR MODULE MOUNT ING TAB CONTINUITY FIND WHY NO 1...

Page 236: ...HIFTER SWITCH 5 WIRING CONNECTIONS TEST RIDE UNIT YES AWD LAMP OFF FIND WHY 1 NO AC VOLTAGE ON YELLOW RED WIRE TO LR 2 FAULTY CHARGING SYSTEM COM PONENT 3 WIRING CONNECTIONS 4 FAULTY LR MODULE NO THIS...

Page 237: ...lator connector Is it Check regulator rectifier connections and ground battery connections cir cuit breaker and connecting wires Repair or replace faulty wiring or components If all of the previous te...

Page 238: ...le 3 With engine off and the key and kill switch in the ON position the ammeter should read negative amps battery discharge Reverse meter leads if a positive reading is indicated 4 Shift transmission...

Page 239: ...water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes w...

Page 240: ...ce battery 1 Remove battery from the vehicle 2 Test battery with a voltage meter or load tester to determine battery condition This will determine the length of time required to charge the battery to...

Page 241: ...ttery is stored or used in a partially charged condition or with low electrolyte levels hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery NOTE Use...

Page 242: ...form the following steps NOTE This section contains information for both Conventional Lead Acid batteries and Sealed Low Maintenance batteries Before service identify the battery type in the vehicle U...

Page 243: ...einstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Remove the battery 4 Remove the filler caps and add distilled water only as needed to bring ea...

Page 244: ...BATTERY LOAD TEST CAUTION To prevent shock or component damage remove spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on mach...

Page 245: ...ring 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 g...

Page 246: ...uch a halogen lamp with bare fingers Oil from your skin leaves a residue causing a hot spot which will shorten the life of the lamp Hold the bulb by the base only 1 Grasp base of bulb at back of housi...

Page 247: ...NEUTRAL LIGHT CIRCUIT OPERATION Power is supplied to the transmission switch from the Red White wire when the key is on When neutral is selected power flows through the switch to the Green White wire...

Page 248: ...e battery positive and the red lead to the solenoid end of the battery to solenoid wire De press starter button Reading should be less than 1 V D C Clean the battery to solenoid cable ends or replace...

Page 249: ...esting 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...

Page 250: ...sulation 1 Note the alignment marks on both ends of the starter motor casing These marks must align during reassembly 2 Remove the two bolts washers and sealing O Rings Inspect O Rings and replace if...

Page 251: ...hes Measure length of brushes and replace if worn past the service limit Replace springs if they are discolored or have inadequate tension 4 Inspect surface of commutator for wear or discoloration See...

Page 252: ...replaced STARTER ASSEMBLY 1 Place armature in field magnet casing 2 Place shims on drive end of armature shaft with phenolic washer outermost on shaft Engage tabs of stationary washer in drive end ho...

Page 253: ...e with the end bent in a hook and pick the old spring out of its channel Slide it off the end of the shaft Slide the new spring over the overrun clutch and into the spring groove Make sure that the sp...

Page 254: ...ELECTRICAL 10 38 NOTES...

Page 255: ...ELECTRICAL WIRING DIAGRAM 2009 SCRAMBLER 500...

Page 256: ...ELECTRICAL WIRING DIAGRAM 2009 SCRAMBLER 500...

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