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Polaris SPORTSMAN 400 2003, Service Manual

The Polaris SPORTSMAN 400 2003 is a durable and reliable off-road ATV. To ensure smooth operation and maintenance, it is essential to have the 2003 Polaris SPORTSMAN 400 Service Manual, available for free download at manualshive.com. This comprehensive manual provides detailed instructions and diagrams for hassle-free maintenance and repairs.

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MAINTENANCE

2.28

machine is in neutral and repeat Steps 2 and 3.
SEE WARNING

5.

If particles are still suspected to be in the muffler,
drive the machine onto the incline so the front of
the machine is one foot higher than the rear. Set
the hand brake and block the wheels. Make sure
the machine is in neutral and repeat Steps 2 and
3. SEE WARNING

6.

Repeat steps 2 through 5 until no more particles
are expelled when the engine is revved.

7.

Stop the engine and allow the arrestor to cool.

8.

Reinstall the clean out plugs.

BRAKE SYSTEM INSPECTION

The following checks are recommended to keep the
brake system in good operating condition. Service life
of brake system components depends on operating
conditions. Inspect brakes in accordance with the
maintenance schedule and before each ride.

S

Keep fluid level in the master cylinder
reservoir to the indicated level inside
reservoir.

S

Use Polaris DOT 3 Brake Fluid (PN
2870990).

Parking Brake
Lock

Sight
Glass

Min

Max

Rear Master Cylinder Reservoir

S

Check brake system for fluid leaks.

S

Check brake for excessive travel or
spongy feel.

S

Check

friction

pads

for

wear,

damage or looseness.

S

Check surface condition of the disc.

BRAKE PAD INSPECTION

Pads should be changed when the friction material is
worn to 3/64

(.1 cm), or about the thickness of a dime.

3/64

(.1cm)

Minimum
Thickness

HOSE/FITTING INSPECTION

Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.

AUXILIARY BRAKE TESTING

The auxiliary brake should be checked for proper
function.

Auxiliary Foot Brake Pedal

Floor
Board Surface

Full Height

Full
Engagement

1.

Support the rear wheels off the ground.

2.

While turning the rear wheels by hand, apply the
auxiliary foot brake. This brake should not stop
the wheels from turning until the lever is half way
between its rest position and bottoming on the
footrest.

Enfocus Software - Customer Support

Summary of Contents for SPORTSMAN 400 2003

Page 1: ...2003 SPORTSMAN 400 500 SERVICE MANUAL PN 9918065 The Way Out ...

Page 2: ...ndex is provided at the end of the manual for location of specific page numbers and service information Keep this manual available for reference in the shop area At the time of publication all information contained in this manual was technically correct However all materials and specifications are subject to change without notice Comments or suggestions about this manual may be directed to Polaris...

Page 3: ...cing the ATV CAUTION A CAUTION indicates special precautions that must be taken to avoid personal injury or ATV or property damage NOTE A NOTE provides key information to clarify instructions Trademarks Polaris acknowledges the following products mentioned in this manual FLEXLOC Registered Trademark of SPS Technologies Loctite Registered Trademark of the Loctite Corporation STA BIL Registered Trad...

Page 4: ...EX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10 ELECTRICAL ...

Page 5: ......

Page 6: ...ions 1 2 1 4 Specifications Sportsman 400 1 5 1 6 Specifications Sportsman 500 H O 1 7 1 8 Publication Numbers 1 9 Paint Codes 1 9 Replacement Keys 1 9 Standard Torque Specifications 1 10 Torque Conversion Table 1 11 1 12 Decimal Equivalent Chart 1 13 Conversion Table 1 14 Tap Drill Charts 1 15 Glossary of Terms 1 16 1 17 ...

Page 7: ... No Individual Serial No Body Style Check Digit World Mfg ID This could be either a number or a letter ENGINE SERIAL NUMBER LOCATION Whenever corresponding about an engine be sure to refer to the engine model number and serial number This information can be found on the sticker applied to the recoil housing on the right side of engine A An additional number is stamped on the center top of crankcas...

Page 8: ...SPORTSMAN 400 500 47 in 114 cm 11 in 28 cm 46 in 117 cm 46 in 117 cm 51 in 129 5 cm 81 in 205 7 cm 51 in 128 cm 400 500 85 in 216 cm GENERAL INFORMATION 1 3 MACHINE DIMENSIONS ...

Page 9: ... Black 2 2 ENGINE Type 4 Cycle Single Cyl Displacement 425 cc Bore 3 461I 87 9mm Stroke 2 756I 70mm Valve Clearance In Ex 0 006 0 006I TDC on compression Compression Ratio 9 2 1 Full Stroke Cooling Liquid Lubrication Type Dry Sump Operating RPM 200 6300 RPM Idle RPM 200 lights off 1200 RPM Compression Pressure Std 15 CARBURETION Type BST 34 Mikuni Main Jet 167 5 Pilot Jet 40 Jet Needle 4GAC33 3 Ne...

Page 10: ...CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type Shaft Drive Front Suspension MacPherson Strut Gear Reduction Low 6 69 1 Tow Capacity 1225 lbs 555 6 kg Gear Reduction Rev 5 17 1 Turning Radius 65I 165 1 cm Gear Reduction High 3 34 1 Toe Out 1 8I 1 4I 3 6 35 mm Front Drive Ratio 2 1 Ground Clearance 11I 27 94 cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02 cm Final Drive Ratio 3 16 1 Rea...

Page 11: ... EBS EBS require no helix spring adjustment ENGINE Type 4 Cycle Single Cyl Displacement 499 cc Bore 3 6248I 92mm Stroke 2 955I 75mm Valve Clearance In Ex 0 006 0 006I TDC on compression Compression Ratio 10 2 Full Stroke Cooling Liquid Lubrication Type Dry Sump Operating RPM 200 6500 RPM Idle RPM 200 lights off 1200 RPM Compression Pressure Std 15 CARBURETION Type BST 40 Mikuni Main Jet 152 5 Pilo...

Page 12: ...Style Gen IV Chain Type Shaft Drive Front Suspension MacPherson Strut Gear Reduction Low 6 69 1 Tow Capacity 1225 lbs 555 6 kg Gear Reduction Rev 5 17 1 Turning Radius 65I 165 1 cm Gear Reduction High 3 34 1 Toe Out 1 8I 1 4I 3 6 35 mm Front Drive Ratio 2 1 Ground Clearance 11I 27 94 cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02 cm Final Drive Ratio 3 16 1 Rear Suspension Progressive ...

Page 13: ... 8520147 Order direct from Midwest Industrial Coatings 952 942 1840 Mix as directed COLD WEATHER KITS FOR 4 CYCLE ATVS Oil Tank Cover PN 2871874 Engine Heater PN 2871507 REPLACEMENT KEYS Replacement keys can be made from the original key To identify which series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number Series Part Numbe...

Page 14: ...3 5 0 60 6 9 10 32 31 3 6 49 5 6 68 7 8 Torque ft lbs Nm 1 4 20 5 7 8 11 12 16 1 4 28 6 8 10 14 14 19 5 16 18 11 15 17 23 25 35 5 16 24 12 16 19 26 29 40 3 8 16 20 27 30 40 45 62 3 8 24 23 32 35 48 50 69 7 16 14 30 40 50 69 70 97 7 16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 Metric 6 x 1 0 72 78 In lbs 8 x 1 25 14 18 ft lbs 10 x 1 25 26 30 ft lbs To convert ft ...

Page 15: ...906 10 mm 3937 13 32 4063 27 64 4219 11 mm 4331 7 16 4375 29 64 4531 15 32 4688 12 mm 4724 31 64 4844 1 2 5 13 mm 5118 33 64 5156 17 32 5313 35 64 5469 14 mm 5512 9 16 5625 37 64 5781 15 mm 5906 19 32 5938 39 64 6094 5 8 625 16 mm 6299 41 64 6406 21 32 6563 17 mm 6693 43 64 6719 11 16 6875 45 64 7031 18 mm 7087 23 32 7188 47 64 7344 19 mm 7480 3 4 75 49 64 7656 25 32 7813 20 mm 7874 51 64 7969 13 ...

Page 16: ...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 qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 Liters l Liters l x 1 057 US quarts US qt US gallons US gal x 3 785 Liters l Li...

Page 17: ... 64 1 1 8 12 1 3 64 1 1 4 7 1 7 64 1 1 4 12 1 11 64 1 1 2 6 1 11 32 1 1 2 12 1 27 64 1 3 4 5 1 9 16 1 3 4 12 1 43 64 2 4 1 2 1 25 32 2 12 1 59 64 2 1 4 4 1 2 2 1 32 2 1 2 4 2 1 4 2 3 4 4 2 1 2 3 4 2 3 4 METRIC TAP DRILL SIZES Tap Size Drill Size Decimal Equivalent Nearest Fraction 3 x 50 3 x 60 4 x 70 4 x 75 5 x 80 5 x 90 6 x 1 00 7 x 1 00 8 x 1 00 8 x 1 25 9 x 1 00 9 x 1 25 10 x 1 25 10 x 1 50 11...

Page 18: ...icator 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 instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Electrical Open Open circuit An electrical circuit which isn t complete Electrical Short Short circuit ...

Page 19: ...creases 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 referred to based on normal operating position of the driver RPM Revolutions per minute Secondary Clutch Driven clutch on chaincase or jackshaft Seized Piston Galling of the sides of a piston Usually t...

Page 20: ...arburetor Adjustments 2 11 2 13 Fuel System 2 13 2 14 Compression Test 2 15 Battery Maintenance 2 15 2 16 Electrical 2 16 Coolant System Maintenance 2 17 2 18 Air Filter Service 2 18 2 20 Air Box Sediment Tube Service 2 20 Breather Filter 2 20 Recoil Housing 2 20 Oil Change Filter 2 21 2 23 Valve Clearance 2 23 2 24 Steering and Toe Alignment 2 24 2 26 Front Hub Maintenance 2 26 2 27 Exhaust Syste...

Page 21: ...rs Monthly 200 320 Inspect and replace if necessary Oil Tank Vent Hose 100 hrs 12 months 1000 1600 Inspect hose routing hose condition EH Valve Clearance 100 hrs 12 months 1000 1600 Inspect Adjust E Idle Speed As required As required Adjust H Throttle Cable ETC Switch 50 hrs 6 months 500 800 Inspect Adjust Lubricate Replace if necessary Choke Enricher Cable 50 hrs 6 months 500 800 Inspect Adjust L...

Page 22: ...t Daily Pre Ride Inspection Item H Brake Fluid 200 hrs 24 months 2000 3200 Change Every Two Years Brake Fluid Level Pre ride Pre ride Inspect Daily Pre Ride Inspection Item Brake Lever Travel Pre ride Pre ride Inspect Daily Pre Ride Inspection Item H Brake Pad Wear 10 hrs Monthly 100 160 Inspect Periodically Auxiliary Brake Adjustment As required As required Inspect Deflection Daily Adjust Brake S...

Page 23: ...or box should be at the center line of the shift selector plungers Do not overfill or the selector may hydro lock 8 4 Coolant Level Polaris Premium 60 40 Pre mixed Antifreeze Coolant PN 2871323 or a 50 50 mixture high quali ty antifreeze coolant and distilled water Fill reservoir tank to full line Add if neces sary If reservoir was empty or extremely low allow engine and cooling system to cool com...

Page 24: ...1312 Grease Gun Kit 2871329 Dielectric Grease Nyogelt Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count Additives Sealants Thread Locking Agents Misc 2870585 Loctitet Primer N Aerosol 25 g 2871956 Loctitet Thread Sealant 565 50 ml 6 Count 2871949 Loctitet Threadlock 242 50 ml 10 Count 2871950 Loctitet Threadlock 242 6 ml 12 Count 2871951 Loctitet Threadlock 262 50 m...

Page 25: ...ol 5 2870506 Clutch Puller 6 9314177 Clutch Holding Wrench 6 2871358 Clutch Holding Fixture 6 2870341 Drive Clutch Spider Removal and Install Tool 6 2870654 Clutch Offset Alignment Tool 6 2870913 Driven Clutch Puller 6 2870910 Roller Pin Tool 6 2871226 Clutch Bushing Replacement Tool Kit 6 2870386 Piston Pin Puller 6 2872292 EBS Clutch Alignment Tool 6 2201379 EBS Bushing Replacement Kit 6 8700220...

Page 26: ...level inside reservoir As required Change fluid every 2 years 4 Front Gear case Oil Premium Front Gear case Lube PN 2871653 Add to bottom of fill plug threads Change annually More often under severe use such as operated in water or under severe loads Semi annually or 50 hours of operation refer to Maintenance Schedule for additional information More often under severe conditions operating in water...

Page 27: ...un Semi annually 7 U Joints Front Prop Shaft Premium U Joint Grease PN 2871551 Locate Fittings and Grease Semi annual ly 8 Propshaft Yoke Premium U Joint Grease PN 2871551 Locate fittings and grease 3 pumps maximum Annually More often under severe use such as operated in water or under severe loads Semi annually or 50 hours of operation refer to Maintenance Schedule for additional information More...

Page 28: ...s drained completely install a new sealing washer and install the drain plug Torque to 14 ft lbs 19 Nm 5 Add the proper lubricant through the dipstick hole until the oil level is between the upper and lower limits Do not overfill 6 Check for leaks 7 Reinstall skid plate if removed in Step 1 FRONT GEARCASE LUBRICATION The gearcase lubricant level should be checked and changed in accordance with the...

Page 29: ...ptoms include S No All Wheel Drive light S Noise on deceleration S Inability to engage a gear S Excessive gear clash noise S Shift selectors moving out of desired range NOTE When adjusting linkage always adjust both linkage rods The adjustment of one rod can prevent proper adjustment of the other rod Remove necessary components to gain access to shift linkage rod ends i e exhaust heat shield exhau...

Page 30: ...jam nuts must be tightened with both front and rear rod ends parallel to each other If jam nuts are properly tightened the rod should rotate freely 1 4 turn without binding 11 Repeat Steps 7 10 for the High Reverse rod THROTTLE INSPECTION Check for smooth throttle opening and closing in all handlebar positions Throttle lever operation should be smooth and lever must return freely without binding 1...

Page 31: ...RPM such as the PET 2100DX PN 8712100DX 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 pilot screw wrench until engine begins to miss 6 Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM Continue turning counterclockwise ...

Page 32: ...ustment procedure FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions S Always stop the engine and refuel outdoors or in a well ventilated area S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored S Do not overfill the tank Do not fill the tank neck S If you get gasoline in your eyes or if ...

Page 33: ...n direction of fuel flow 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 moisture or sediment from the bowl or before extended periods of storage NOTE The bowl drain screw is located on the bottom left side of the float bowl 1 Turn fuel valve to the off position 2 Place a ...

Page 34: ... engine fasteners and ensure they are tight A A A BATTERY MAINTENANCE WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Anti dote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician im mediately Eyes Flush with water for 15...

Page 35: ...erly routed and not kinked or pinched 10 Coat terminals and bolt threads with Nyogelt grease 11 Reinstall battery cover and holder strap SPARK PLUG 1 Remove spark plug high tension lead Clean plug area so no dirt and debris can fall into engine when plug is removed 2 Remove spark plug 3 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the el...

Page 36: ...TH TYPE Test the strength of the coolant using an antifreeze hydrometer Antifreeze Hydrometer S A 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection S Do not use tap water straight antifreeze or straight water in the system Tap water contains minerals and impurities which build up in the system S Straight water o...

Page 37: ...T LEVEL INSPECTION NOTE This procedure is only required if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry or if overheating is evident the level in the radiator should be inspected and coolant added if necessary WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be ...

Page 38: ...he filter has been soaked with fuel or oil it must be replaced Installation 10 Reinstall pre filter element over main filter Be sure the element covers entire surface of main filter without folds creases or gaps 11 Reinstall filter on main filter mount Place filter clamp over the assembly and tighten NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before rein...

Page 39: ... sure lines are not kinked or pinched RECOIL HOUSING Recoil Drain Crankcase Drain S Drain the housing periodically to remove moisture S Drain the recoil housing after operating the ATV in very wet conditions This should also be done before storing the ATV The drain screw is located at the bottom of the recoil housing Remove the screw with a 10 mm wrench Reinstall screw once housing has been draine...

Page 40: ...FILTER CHANGE WARNING Personal injury can occur when han dling used oil Hot oil can cause burns or skin damage NOTICE Care must be taken to ensure that fluids are contained Be prepared to collect the fluid with suitable containers 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...

Page 41: ... plug 20 Remove dipstick and fill tank with 2 quarts 1 9 L of Polaris Premium 4 Synthetic Oil PN 2871844 21 Place gear selector in neutral and set parking brake NOTE Clamp or pinch off the vent line 2 from the oil tankas shown below in the Oil Pump Priming Procedure for the 500 engine 22 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dip...

Page 42: ...n compression stroke will result in improper valve adjustment Sprocket alignment pin facing up Crankshaft to Camshaft Centerline 6 Rotate engine slowly with recoil rope watching the intake valve s open and close NOTE At this point watch the camshaft sprocket locating pin and slowly rotate engine until locating pin is facing upward directly in line with the crankshaft to camshaft center line as sho...

Page 43: ...ugh entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited NOTE Whenever steering components are replaced check front end alignment Use only genuine Polaris parts WARNING Due to the critical nature of the procedures out lined in this chapter Polaris recommends steering component repair and adjustment be per...

Page 44: ...d See notes below NOTE String should just touch side sur face of rear tire on each side of machine NOTE The steering post arm frog can be used as an indicator of whether the handle bars are straight The frog should always point straight back from the steering post Rear rim measure ment should be 1 16 to 1 8 2 to 3 cm more than front rim measure ment Measure from string to rim at front and rear of ...

Page 45: ...rement at the rear B TOE ALIGNMENT ADJUSTMENT If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure handlebars are straight ahead before determining which tie rod s need adjustment CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end...

Page 46: ... from contact with ex haust components S To reduce fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor S Wear eye protection S Do not stand behind or in front of the ve hicle while purging the carbon from the spark arrestor S Never run the engine in an enclosed area Exhaust contains poisonous car bon monoxide gas S Do not go under the machine w...

Page 47: ...ated level inside reservoir S Use Polaris DOT 3 Brake Fluid PN 2870990 Parking Brake Lock Sight Glass Min Max Rear Master Cylinder Reservoir S Check brake system for fluid leaks S Check brake for excessive travel or spongy feel S Check friction pads for wear damage or looseness S Check surface condition of the disc BRAKE PAD INSPECTION Pads should be changed when the friction material is worn to 3...

Page 48: ...e any parts as needed Bleeding If free play is correct and brake pedal travel is still excessive air may be trapped somewhere in the system Bleed the hydraulic auxiliary brake system in a conventional manner following the procedure outlined in Brake Chapter 9 SUSPENSION SPRING PRELOAD ADJUSTMENT Center Spring Adjustment Ring Operator weight and vehicle loading affect suspensionspringpreloadrequire...

Page 49: ...l Nuts 20 Ft Lbs 27 Nm Rear Wheel Nuts 20 Ft Lbs 27 Nm Front Spindle Nut Refer to procedure listed in Chapter 7 Rear Hub Retaining Nut 100 Ft Lbs 136 Nm WHEEL REMOVAL FRONT OR REAR Flange Nuts Flat side against wheel 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the fo...

Page 50: ... use original equipment size and type S The use of non standard size or type tires may affect ATV handling Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Tread Depth 1 8I 3 mm WARNING Operating an ATV with worn tires will in crease the possibility of the vehicle skid ding easily with possible loss of control Worn tires can cause an accident Always replace tires ...

Page 51: ...MAINTENANCE 2 32 NOTES ...

Page 52: ... Lubrication Oil Flow 3 11 3 12 EH50PL Engine Exploded View 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 31 EH50PL Engine Bottom End Disassembly 3 31 3 36 EH50PL Crankcase Bearing Assembly 3 37 3 38 EH50PL Crankshaft End Play Inspection 3 38 3 39 EH50PL Counter Balancer End Play Inspection 3 40 EH50PL Oil Pump Shaft End P...

Page 53: ... 12mm 11 15 15 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm Oil Filter Pipe Fit ting 20mm 36 43 49 59 Nm Oil Hose Fitting 1 8 Pipe Thread 6 5 11 9 15 Nm Oil Pump 6mm 5 6 5 7 9 Nm Oil Pump Case Screw 5mm 1 5 2 2 3 Nm One Way Valve 11mm 14 19 20 25 Nm Recoil Housing 6mm 5 6 5 7 9 Nm Rocker Cover 6mm 7 8 9 11 Nm Rocker Support 8mm 8 10 11 13 Nm Rocker Adjuster Screw 6mm 6 7 8 10 Nm Water Pump I...

Page 54: ... Oil clearance Std 0022 0035 055 090 mm 0022 0035 055 090 mm Limit 0039 10 mm 0039 10 mm Cylinder Head Surface warpage limit 0020 05 mm 0020 05 mm y Standard height 3 870 98 3 mm 3 870 98 3 mm Valve Seat Contacting width In Std 028 7 mm 028 7 mm g Limit 055 1 4 mm 055 1 4 mm Ex Std 039 1 0 mm 039 1 0 mm Limit 071 1 8 mm 071 1 8 mm Valve Guide Inner diameter 2362 2367 6 0 6 012 mm 2362 2367 6 0 6 0...

Page 55: ...h by hand fit at 68 F 20 C Piston Ring Piston ring installed gap Top ring Std 0079 0138 20 36 mm 0079 0138 20 36 mm g g g g Limit 039 1 0 mm 039 1 0 mm Second i Std 0079 0138 20 36 mm 0079 0138 20 36 mm ring Limit 039 1 0 mm 039 1 0 mm Oil ring Std 0079 0276 20 70 mm 0079 0276 20 70 mm g Limit 059 1 5 mm 059 1 5 mm Piston Ring Standard clearance i i i Top ring Std 0016 0031 040 080 mm 0016 0031 04...

Page 56: ...dentification 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 toward the flywheel side of the engine The other numbers are used for identification as to diameter length and design Four stroke engine rings are rectangular profile See text for oil control ring upper rail ...

Page 57: ...r 2 Remove recovery bottle hose from coolant filler 3 Connect a Mity Vact PN 2870975 to radiator and pressurize system to 10 PSI The system must retain 10 lbs of pressure for five minutes or longer If pressure loss is evident within five minutes check radiator all cooling system hoses and clamps or water pump seal Radiator Cap Pressure Test 1 Remove radiator cap and test using a cap tester commerc...

Page 58: ...nkcase It may be necessary to loosen engine mounts and move engine slightly to access water pump Use the Water Pump Mechanical Seal Puller PN 2872105 to replace mechanical seal with engine in frame ENGINE REMOVAL TYPICAL 1 Clean work area 2 Thoroughly clean the ATV engine and chassis 3 Disconnect battery negative cable 4 Remove the following parts as required S Seat S Left and Right Side Covers Re...

Page 59: ...t lines to force air out of system 4 Again remove radiator cap and slowly add coolant to top of fill neck 5 Start engine and observe coolant level in the radiator Allow air to purge and top off as necessary Reinstall radiator cap and bring engine to operating temp Check level in reservoir tank after engine is cool and add coolant if necessary Engine Break In Period 4 Cycle Engine Break In Period i...

Page 60: ...at the end of each stroke S Release the hone at regular intervals and inspect the bore to determine if it has been cleared and to check piston fit NOTE Do not allow cylinder to heat up during honing The thinner areas of the liner around the ports will expand causing uneven bore S After honing has been completed inspect all port opening areas for rough or sharp edges Apply a slight chamfer to all p...

Page 61: ...ion 20 PSI 5500 RPM Polaris 0W 40 Synthetic Engine Hot OIL PRESSURE TEST EH50PL 1 Remove blind plug on front left cylinder head 2 Insert a 1 8 NPT oil pressure gauge adaptor into the cylinder head and attach the gauge 3 Start engine and allow it to reach operating temperature monitoring gauge indicator NOTE Use Polaris Premium 4 Synthetic Engine Lubricant PN 2871281 Oil Pressure at 5500 RPM Engine...

Page 62: ...it passes through the slotted friction bearing located in the stator plate into the 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 directly Oil also passes through an oil jet drilled orifice in the end of the crank pin to the PTO end main bearings and...

Page 63: ...nkcase 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 Fitting Upper Through Cylinder Stud Front Left Indirect Lubrication Prevents oil from draining into crankcase with engine off Bottom fitting is oil exhaust or return to tank Top fitting is oil feed or ...

Page 64: ...ENGINE 3 13 EH50PL ENGINE EXPLODED VIEW Crankcase Cylinder Cylinder Head Crankshaft and Piston Valve Train A ...

Page 65: ...e 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 aligned with the camshaft to crankshaft center line NOTE The cam lobe should be pointing down and valves should have clearance at this point 5 Remove cam chain tensioner plug sealing washer and spri...

Page 66: ...r Spring Free Length 2 320I 5 9 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 damaged ROCKER ARM SHAFT INSPECTION 1 Mark or tag rocker arms to keep them in order for assembly 2 Inspect each rocker arm cam follower surface If there is any damage or uneven wear replace the rocker ar...

Page 67: ...orts 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 screws for wear pitting or damage to threads of the adjuster or locknut Replace all worn or damaged parts NOTE The end of the adjuster screw is hardened and cannot be ground or re faced CAMSHAFT REMOV...

Page 68: ...re 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 Sleeve Decompressor Shaft 10 Slide camshaft out the PTO side of the cylinder head AUTOMATIC COMPRESSION RELEASE REMOVAL INSPECTION NOTE The automatic compression release mechanism can be inspected a...

Page 69: ...the camshaft until the actuator ball is in the lowest position 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 release lever shaft 5 Position camshaft as shown at bottom of illustration at right 6 Place arm of spring under stop pin as shown and push rel...

Page 70: ...Compare to specifications Camshaft Oil Clearance Std 0022 0035I 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 CYLINDER HEAD EXPLODED VIEW EH50PL 1 Remove the two 6mm flange bolts A from cylinder head See next exploded view on next page 2 Loosen each of th...

Page 71: ...ENGINE 3 20 CYLINDER HEAD EXPLODED VIEW EH50PL A EH50PL ...

Page 72: ...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 Using a valve spring compressor A compress the valve spring and remove the ssdplit keeper NOTE To prevent loss of tension do not compress the valve spring more than necessary A 2 Remove spring retainer...

Page 73: ...o 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 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 Measure valve stem in several places Valve Stem Diameter Intake 2343 2348...

Page 74: ...ing 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 protection when performing cylinder head service Valve guide replacement will require heating of the cylinder head Wear gloves to prevent burns Valve Guide Removal Installation 1 Remove all carbon d...

Page 75: ...alled 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 NOTE The guide can also be driven in to the proper depth Inspect the guide closely for cracks or damage if a driver is used Reaming The Valve Guide 5 Allow cylinder head to cool to room temperature App...

Page 76: ...or 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 too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut Valve Seat Width Intake Std 028I 7 mm Limit 055I 1 4 mm Exhaust Std 039I 1 0 mm Limit ...

Page 77: ...e 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 retainer on spring and install valve spring compressor Compress spring only enough to allow split keeper installation to prevent loss of spring tension Install split keepers with the gap even on both sides ...

Page 78: ... engines 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 securely 4 Re check the valve clearance 5 Repeat adjustment procedure if necessary until clearance is correct with locknut secured CYLINDER PISTON REMOVAL AND INSPECTION NOTE Follow engine disassembly pr...

Page 79: ...Support Block PN 2870390 8 Remove dowel pins from crankcase PISTON REMOVAL 1 Remove circlip Note piston directional arrow pointing toward the right Mag side of engine 2 Remove piston circlip and push piston pin out of piston If necessary heat the crown of the piston slightly with a propane torch CAUTION Do not apply heat to the piston rings The ring may lose radial tension 3 Remove top compression...

Page 80: ... of the cylinder for warpage using a straight edge and feeler gauge Cylinder Warpage 002 05 mm 3 Inspect cylinder for wear scratches or damage 1 2 Down From Top of Cylinder 1 2 Up From Bottom X X Y Y X Y 4 Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge Measure in two different directions front to back and side to side on three different levels 1 2 down fr...

Page 81: ...asurement obtained in Step 5 above Piston to Cylinder Clearance Std 0006 0018I 015 045 mm Piston O D Std 3 6204 3 6215I 91 970 91 985 mm PISTON ROD INSPECTION Piston Pin 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 piston pin if out of tolerance 3 Mea...

Page 82: ... A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 If the bottom installed gap measurement exceeds the service limit replace the rings If ring gap is below specified limit file ring ends until gap is within specified range NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings A re bo...

Page 83: ...t gear teeth on starter drive Replace starter drive if gear teeth are cracked worn or broken FLYWHEEL STATOR REMOVAL INSPECTION 1 Remove flywheel nut and washer 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 position of stator plate on crankcase 4 Remove bolts and carefull...

Page 84: ...th for wear or damage 7 Inspect Woodruff key for wear 8 Replace any worn or damaged parts ONE WAY VALVE The one way valve prevents oil from drainingout of the oil tank and into the crankcase when the engine is off It must be clean and have adequate spring pressure in order to seal properly B C D A 1 Remove cap bolt A sealing washer B spring C and one way valve D from PTO side crankcase 2 Inspect f...

Page 85: ...Do not strike the oil pump shaft at an angle or the shaft may bend causing irreparable damage Tap only lightly on the pump shaft if necessary 4 Remove the Mag RH crankcase from the PTO case OIL PUMP REMOVAL INSPECTION A B C 1 Remove pump shaft bearing A and thrust washer B from pump shaft 2 Remove 2 bolts holding pump drive gear C 3 Inspect drive gear teeth for cracks damage or excessive wear 4 Re...

Page 86: ...inner and outer scavenge rotor and inspect pump shaft for 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 Install pump shaft and scavenge rotor drive pin 3 Install outer scavenge rotor inner scavenge rotor and scavenge casing 4 Install outer feed rotor and...

Page 87: ...ns of discoloration scoring or 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 side to side movement and no detectable up and down movement CRANKSHAFT REMOVAL INSPECTION A 1 Remove the shim washer A from the crankshaft 2 Support the PTO side crankc...

Page 88: ... 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 ENGINE DISASSEMBLED NOTE The water pump mechanical seal can be removed without removing the engine Refer to Water Pump Mechanical Seal Installation Replace the pump shaft seal and water pump mechanica...

Page 89: ... 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 may cause engine noise at idle and slow speeds Too little play will side load the bearings which may lead to premature bearing failure CRANKSHAFT END PLAY ADJUSTMENT 1 Make sure all bearings are firm...

Page 90: ... 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 7 from the Total Case Width recorded in Step 6 and record below Total End Play 9 Subtract the thickness of the existing shim from the result of Step 8 to determine if a different shim is required The...

Page 91: ...ured 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 specified range listed at below Counter Balancer Shaft End Play 008 016 02 04 cm OIL PUMP SHAFT END PLAY ADJUSTMENT 1 Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase 2 Measu...

Page 92: ...e crankshaft and balancer gears Install the proper shim washer on the shaft 5 Inspect the oil pump sealing surface on the crankcase Apply a light film of engine oil to the surface and install the oil pump NOTE Do not use gasket sealer on the pump mating surfaces NOTE After engine is assembled and machine is readied for field operation oil pump MUST be primed Follow oil pump priming procedure on Pa...

Page 93: ...re can result in a bent water pump shaft Pump shaft replacement requires engine removal and crankcase separation Use caution while performing this procedure Make sure that the puller is parallel to the shaft at all times Do not place side loads on the water pump shaft or strike the puller or shaft in any way Ill 1 Impeller Sealing Washer Coolant Drain Bolt Mechanical Seal Oil Seal Sealing Washer C...

Page 94: ...until the remaining portion of mechanical 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 seal This tool is available separately and it is also included in the Crankshaft Water Pump Seal Installation Kit PN 2871283 ONE WAY VALVE INSTALLATION Install the on...

Page 95: ...ion 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 See ILL 1 4 Install the second ring with the R mark facing up Position the end gap toward the rear intake side of the piston 5 Install the top ring chrome faced with the R mark facing up and the end ...

Page 96: ...ylinder 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 Ont PN RCL30 and install the compressor following manufacturers instructions CAUTION Make sure the oil control ring upper rail tab is positioned properly in the notch of the piston Verify all ring end...

Page 97: ...hreads 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 Torque bolts to 51 ft lbs 70 Nm Loosen bolts evenly 180 1 2 turn Loosen bolts again another 180 1 2 turn Torque bolts to 11 ft lbs 15 Nm From this point tighten bolts evenly 90 1 4 turn Finally tight...

Page 98: ...outward 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 the cam sprocket alignment pin A is directly in line with the crankshaft camshaft centerline B 6 Install the sprocket on the camshaft Apply Loctitet 242 PN 2871949 to the cam sprocket bolts and torq...

Page 99: ...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 100: ...o 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 or an equivalent sealer to the stator plate outer surface and install a new O Ring 4 Install the stator plate being careful not to damage the seal Align timing reference marks on the plate and crankc...

Page 101: ...rfaces 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 bolts and tighten evenly Rocker Shaft Support Tower Bolt Torque 9 ft lbs 12 Nm Rocker Shaft Locating Bolt Torque 6 ft lbs 8 Nm 7 Adjust valves according to the valve adjustment procedure found in Ch...

Page 102: ...er 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 A 12 Inspect plate for wear or damage Inspect plate friction spring for wear damage and proper tension The spring should fit tightly on friction plate 13 Remove ratchet pawl with spring and inspect Replace spring or ratchet p...

Page 103: ...23 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 as viewed from ratchet side of reel 3 Lock rope into notch on outer edge of reel 4 Apply a small amount of grease or equivalent to the center post of the housing and the bushing Open end here 5 Install reel into housing ma...

Page 104: ... 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 Will Not Idle S Restricted carburetor pilot system S Carburetor misadjusted S Choke not adjusted properly S Low compression S Crankcase breather restricted Engine Idles But Will Not Rev Up S Spark plu...

Page 105: ... 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 Restricted system mud or debris in radiator fins or restriction to air flow passages blocked in radiator lines pump or water jacket S Lean mixture restricted jets vents fuel pump or fuel valve S Fuel ...

Page 106: ... Jetting 4 5 Main Jet Pilot Jet Part Numbers 4 5 CV Carburetor System Function 4 Cycle 4 6 CV Carburetor Vent System 4 Cycle 4 6 CV Carburetor Operation 4 6 4 8 Disassembly Notes CV Carburetor 4 8 4 9 Cleaning CV Carburetor 4 9 Inspection CV Carburetor 4 10 Assembly CV Carburetor 4 10 Float Adjustment CV Carburetor 4 11 Needle Seat Leakage Test 4 11 Fuel Level 4 12 Fuel Pump Service 4 12 4 13 Trou...

Page 107: ...g 19 E Ring 20 Cap 21 Screw 22 Drain Screw 23 O Ring 24 Washer 25 Adjuster 26 Spring 27 Pilot Jet 28 Main Jet 29 Washer 30 Jet Needle 31 Float Assembly 32 Float Body Assembly 33 Float Pin 34 Needle Valve 35 O Ring 36 O Ring 37 Filter 38 Screw 39 Screw 40 Screw 41 Guide Holder 42 Spring 43 Plunger Assembly 44 Spring Washer 45 Screw 46 Air Jet 47 Cable Guide 48 Spring 49 Ring 50 Adjust Screw 51 Scre...

Page 108: ... 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 Pilot Screw 21 Spring 22 Washer 23 O Ring 24 Pilot Jet 25 Valve Inlet Needle 26 Shaft Seal 27 O Ring 28 Air Jet 29 Choke Plunger Guide 30 Spring 31 Choke Plunger 32 Cap 33 O Ring 34 Jet Block Assembly ...

Page 109: ...rward Cap Seal Foam Gasket Vent Line Mounting Bracket Foil Fuel Valve Knob Fuel Valve Fuel Outlets Spacer Foil Fuel Tank Fuel Valve Engine Filter Fuel Pump Carburetor Fuel Tank Vent Carburetor Vent Fitting Screens L L Located Above Oil Tank FUEL FLOW ...

Page 110: ...for an altitude of 0 6000 ft 0 1800 meters and ambient temperatures between 40 and 80 F 5 to 26 C Carburetors must be re calibrated if operated outside this temperature and or altitude range The jetting installed in production is not intended for all altitudes and or temperatures In addition air screw pilot screw adjustments and PVT adjustments may be required to suit operating conditions CARBURET...

Page 111: ...mid 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 restrictions and be properly routed This allows fuel to flow in the proper amount and prevents contaminants from entering the carburetor MIKUNI CV CARB OPERATION The constant velocity carburetor incor...

Page 112: ...Mikuni 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 3 where it mixes with air coming in through pilot air jet 4 The mixture then goes up through pilot passage to pilot screw 5 A part of the mixture is discharged into the main bore out of bypass ports ...

Page 113: ...3 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 main jet 4 and the metered fuel enters needle jet 5 in which it mixes with the air admitted through main air jet 6 to form an emulsion The emulsified fuel then passes through the clearance between n...

Page 114: ... cleaner in your 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 plugs Do not soak rubber or plastic components such as the vacuum slide diaphragm needle seat screen or O Rings in caustic cleaning solutions Irreparable damage may occur Do not use agitat...

Page 115: ... 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 pressure tested after assembly Good Condition Worn Deposits Wear areas Seat Needle CARBURETOR ASSEMBLY Inspect the diaphragm A for holes deterioration or damage Make sure the diaphragm is pliable but no...

Page 116: ...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 34 13 0mm 51 1 mm BST 40 14 7mm 58 1 mm NOTE On BST 40 carburetors it is important to press in on the float assembly as shown to fully seat the float assembly BST 40 BST 34 2 Measure the height from the float bowl mating surface to the top of step in float...

Page 117: ...line fits tightly on fitting Position hose along side of carburetor as shown 1 5 mm 060 Bowl Mating Surface 2 Open bowl drain screw by turning counterclockwise approximately two turns Start and run engine for 3 to 5 seconds to allow fuel level to stabilize in the line If level is out of specification remove carburetor and inspect inlet needle and seat float height passages etc NOTE If a line was r...

Page 118: ... and water Carburetor cleaner may be used to clean the pump body when the check valves are removed CAUTION Some carburetor cleaners are very caustic and should not be used to clean the non metal parts of the fuel pump 3 Check the sealing surfaces of the pump body and covers Carefully remove all traces of old gasket and check the surfaces for damage Replace diaphragms and gaskets as a set 4 Reassem...

Page 119: ...G 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 Ring G Float level too high G Poor fuel quality old fuel G Loose jets G Worn jet needle needle jet or other carburetor parts G Dirty carburetor air bleed passages or jets G Weak or damaged vacuum pisto...

Page 120: ...de Panel Removal 5 3 Body Assembly Exploded View 5 4 Headlight Pod Exploded View 5 5 Steering Assembly Exploded View 5 6 A Arm Replacement 5 7 Rear Suspension Assembly 5 8 Strut Assembly Exploded View 5 9 Front Strut Cartridge Replacement 5 10 Front Strut Ball Joint Replacement 5 11 Steering Post Assembly 5 11 Decal Replacement 5 11 ...

Page 121: ...r Spring Compression Tool 2871572 Strut Rod Wrench 2871573 LH Strut Spring Compressor 2871574 RH Strut Spring Compressor 7052069 Charging Needle 2200421 Gas Shock Recharging Kit 2871352 Shock Rod Holding Tool 2871199 Seal Sleeve Installation Tool Kit 2870872 Shock Spanner Wrench 2871351 Foxt Shock IFP Depth Tool COVER PANEL REMOVAL To Remove Perform These Steps Seat S Pull release lever at the rea...

Page 122: ...s have been snapped and unsnapped a few times Pull forward and out to disengage two rear tabs Step 1 1 Remove seat Grasp rear of side panel near rear cab With a quick and firm motion pull the panel forward and outward to disengage the two rear tabs Push down to disengage top rear two tabs Step 2 2 Place hand on top of side panel behind the fuel tank With a quick and firm motion push down on the si...

Page 123: ...ab Assembly Seat Latch Release Storage Rear Mud Guard Rear Cab Side Cover Front Cover Front Cab Footrest Front Mud Guard Pull UP on rear of seat and back to disengage tabs at front of seat NOTE All warning information labels must be in place when body parts are assembled Splash Guard ...

Page 124: ...e D S Remove headlight with adjuster S Remove two screws securing bottom half of pod E Assembly S Install bottom of pod onto handlebar and secure to brackets S Install key switch choke cable and headlight S Connect 12V power outlet where applicable S Connect headlight S Connect speedometer connectors to speedometer S Install top of pod onto bottom half making sure interlocking tabs mate properly S...

Page 125: ...rd rear of machine B 1 2 1 30 ft lbs 41 Nm A 2 12 14 ft lbs 17 19 Nm 40 45 ft lbs 54 61 Nm Steering Post Steering Post Arm Frog 1 2 NOTE To avoid damage to tie rods and other steering components be sure to install tie rod end bolts in the proper direction The steering post arm bolt B points up the rod end bolts A point down Be sure inner rod ends are placed between the steering post arms Apply Loc...

Page 126: ... existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 9 Attach A arm to hub strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If cotter pin holes are not aligned tighten nut slightly to align Installa newcotter pin with open ends toward rear of machine Bend both ends in opposite directions around nu...

Page 127: ...Machine 17 ft lbs 24 Nm 35 ft lbs 48 Nm Upper Control Arm Orientate Bushings Correctly 30 ft lbs 41 Nm 30 ft lbs 41 Nm Lower Control Arm 35 ft lbs 48 Nm 100 ft lbs 136 Nm 20 ft lbs 27 Nm 17 ft lbs 24 Nm 35 ft lbs 48 Nm 30 ft lbs 41 Nm Rear Front Bushing Orientation ...

Page 128: ...nt 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 Seal Sleeve Install with Seal Sleave Instal lation Kit PN 2871199 Washer Upper Pivot Ball Lower Pivot Ball Washer Spacer Rubber Spring Retainer Spring Bolt Spacer Washer Clamp Wire retainer Hub Coil Spr...

Page 129: ... lbs 21 Nm BALL JOINT REPLACEMENT NOTE Refer to the illustration on the previous page for this procedure 1 Loosen front wheel nuts slightly 2 Elevate and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure 3 Remove wheel nuts and wheels A B C D E F 4 Remove cotter pin A from ba...

Page 130: ...rks that are sometimes left after a fender or cab is bent flexed or damaged WARNING The following procedure involves the use of an open flame Perform this procedure in a well ventilated area away from gasoline or other flammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue To flame treat the decal area 1 Pass the flame of a propane torch back an...

Page 131: ...BODY STEERING SUSPENSION 5 12 NOTES ...

Page 132: ... 10 6 12 Drive Clutch Assembly 6 12 6 13 Drive Belt Tension 6 13 Drive Belt Removal Inspection 6 14 6 15 Drive Belt Installation 6 15 Clutch Alignment Offset 6 16 Drive Clutch Bushing Service 6 17 6 19 Driven Clutch Disassembly Inspection 6 19 6 20 Driven Clutch Assembly 6 21 Driven Clutch Bushing Service 6 21 6 23 EBS Exploded View 6 24 EBS Drive Clutch Disassembly Inspection 6 25 6 26 EBS Driven...

Page 133: ...The Driven Clutch and 3 The Drive Belt The internal components 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 engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or variations of components at random...

Page 134: ...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 Pages 6 11 6 12 3 Sheave Faces Clean and inspect for wear 4 PVT System Sealing Refer to appropriate illustrations and photos The PVT system is air cooled by fins on the drive clutch stationary sheave Th...

Page 135: ...s Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Continuous operation at the point of engagement initial vehicle movement increases PVT temperatures and component we...

Page 136: ...ive belt removal 6 Remove drive clutch retaining bolt and remove drive clutch using puller Drive Clutch Puller PN 2870506 Clutch Holding Wrench PN 9314177 7 Remove driven clutch retaining bolt and driven clutch Use puller if necessary Driven Clutch Puller PN 2870913 8 Remove driven clutch offset spacers from the transmission input shaft NOTE Remember to keep spacers in order for proper clutch offs...

Page 137: ... B C Inner Cover Bolt Torque 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 7 Install clutch offset spacer s on transmission input shaft Offset Spacer 8 Clean splines inside driven clutch and on the transmission input shaft 9 Apply a light film of grease to the splines on the shaft 10 Install the driven clutch washer ...

Page 138: ...LUTCH EXPLODED VIEW Outer Cover Exhaust Duct Inner Cover Seal Inlet duct Retainer Clip Inner Cover Outer Cover Seal Drive Clutch Mark with permanent marker before disassembly Teflont coated brass bushing Teflont coated brass bushing Drain Plug Cover Bolts ...

Page 139: ... its compression rate This may result in complete stacking of the coils and subsequent clutch component failure Measuring Spring Length With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Dis...

Page 140: ...ent RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance clutch balance engagement and shifting characteristics PN 5630513 50 5 gr PN 5630509 55 gr 55 16 PN 5630279 43 gr PN 5630418 50 gr PN 5630095 53 gr 53 PN 5630709 44 gr PN 5630710 46 gr PN 5630711 47gr RH BH 10 10 10 WH ...

Page 141: ...by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT system it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures BUTTON TO TOWER CLEARA...

Page 142: ...wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See Page 6 8 Inspect shaft SPIDER REMOVAL 1 Remove the limiter nut using the Clutch Spider Nut Socket PN 2870338 Install clutch in holding fixture and loosen the spider counterclockwise using Clutch Spider Install Tool PN 2870341 Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 NO...

Page 143: ...ing or bearing surface of the new pin during installation 4 Rubber backed buttons can and should be usedin all ATV clutches if the hollow roller pin is changed to a solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pin It is recommended to switch all buttons to the rubber version during service if needed DRIVE CLUTCH REASSEMBLY NOTE It is important that the ...

Page 144: ... balance Inverting the clutch while initially tightening the spider will help position the washers Spacer washers 6 Install limiter nut on top of spider using the Clutch Spider Nut Socket PN 2870338 Torque to 15 ft lbs Reinstall shift weights using new lock nuts on the bolts 7 Reinstall clutch spring Engine Rotation Nut on trailing side 8 Reinstall cover aligning X mark with other marks Torque cov...

Page 145: ...ed in the same direction NOTE Normally positioned so part numbers are easily read 3 To remove drive belt apply brake pull upward and rearward on belt to open driven clutch sheaves pull out and down on belt to slip over the driven clutch outer sheave NOTE When reinstalling the belt with the drive clutch and driven clutch already removed follow these steps G Install the driven clutch G Install the b...

Page 146: ...stance to obtain proper belt deflection Belts which measure shorter than 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 Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See Troubleshoot...

Page 147: ...t if necessary Center line Measure offset above and below centerline NOTE On some models minor adjustments can be made by adding shims between the frame and front lower left engine mount to increase the distance at point A If a shim is present it can be removed to decrease the distance at point A Shim Kit PN 2200126 CLUTCH OFFSET Important Inspect clutch alignment and center distance before adjust...

Page 148: ... securely into 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 Adapter 8 PN 5020632 onto the Piston Pin Puller PN 2870386 4 Insert the Number Two Adapter 10 PN 5020633 into the bushing from belt side as shown With towers pointing toward vise slide sheave...

Page 149: ...e onto puller rod 4 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 5 Turn sheave and barrel together counterclockwise until bushing is seated 6 Remove nut from puller rod and set aside 7 Remove sheave from puller 8 Remove installation tool DRIVE CLUTCH COVER BUSHING REMOVAL Main Puller Adaptor 8 Piston Pin Puller PN 2870386 1 Install the Main Puller Ad...

Page 150: ...shing 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 tighten Turn puller barrel to apply more tension if needed 4 Turn clutch cover and barrel together counterclockwise on puller rod until bushing is seated 5 Remove nut from puller rod and take installation ...

Page 151: ... 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 remain between the sheaves when adjusting belt deflection Inspect bushings for wear Moveable Sheave Bushing Inspection Replace the bushing if more brass than Teflont is visible on the bushing Re fer to bus...

Page 152: ...quicker backshift or downshift when pulling or negotiating a hill for example The least amount of tension will create a slower downshift and a harder upshift Align boss spline to install helix 4 Line up boss spline and push helix down until it engages the splines 1 2 to 3 4 1 3 turn 5 While holding downward pressure on helix wind moveable sheave counterclockwise approximately 1 3 turn 120 6 Push h...

Page 153: ...aller diameter toward bushing to be removed See illustration 6 Install sheave onto puller 7 Install nut onto puller rod and tighten by hand Turn puller barrel for further tension if needed 8 Turn clutch sheave counterclockwise until bushing is removed Repeat Steps 5 8 for other bushing 9 Remove nut from puller rod and set aside 10 Remove adapters from puller 11 Remove bushing and removal tool from...

Page 154: ...of new bushing 3 Install sheave onto puller with new bushing upward as shown Install the Number Two Puller Adapter 10 PN 5020633 4 Install nut onto puller rod and hand tighten against installation tool 5 Turn clutch sheave counterclockwise until bushing is seated 6 Remove nut from puller rod and set aside ...

Page 155: ...ay Clutch Drive 2 25 PTFE Washer Washer Ramp Flat Spacer Compression Spring Screw Drive Belt PTFE Washer Retaining Ring Flat Washer Drive Clutch Assembly Driven Clutch Assembly Cover Bushing Roller Bushing Assembly Retaining Ring Bushing Bushing Ramp Bushing Torque to 200 Ft Lbs 271 Nm Roller One Way Clutch Driven Spider Lock Nut ...

Page 156: ...Verify there is no binding or rough spots When rotated counterclockwise the clutch should lock to the shaft without slipping If problems are noted in either direction continue with disassembly DRIVE CLUTCH INSPECTION NOTE Remove cover spring and spider following instructions for drive clutch removal then proceed as follows 1 Remove moveable sheave spacer sleeve and the brass washer Visually inspec...

Page 157: ...dard 030 76mm Service Limit 025 64mm MOVEABLE SHEAVE BUSHING INSPECTION 1 Inspect the Teflont coating on the moveable sheave bushing Inspect BOTH sheaves for signs of wear grooving or cracking Clean surfaces with a 3Mt pad if needed Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflont is visible on the bushing Refer to bushing replacement in this chapter EBS DRIV...

Page 158: ... the helix side or the one way clutch seals may be damaged Do not disassemble from this side 4 Place the driven assembly into the clutch holder Push helix inward Remove snap ring washer helix and spring NOTE The spring is a compression spring only and has no torsional wind NOTE Rotating the moveable sheave so that the rollers are not in contact with either helix ramp surfaces will lessen the effor...

Page 159: ...on of the roller retaining screws Do not allow locking agent to contact the inside of the rollers Do not lubricate the roller or roller pin Roller Dry Locking Agent Applied To New Screws Apply Loctitet 680 To Tapered Portion Of Screw Heat Area Lightly DRIVEN CLUTCH DISASSEMBLY INSPECTION CONT D 7 Inspect moveable sheave bushing for wear Inspect BOTH sheaves for signs of wear grooving or cracking C...

Page 160: ... Nut C 6 With towers pointing toward the vise slidesheave onto puller rod 7 Install removal tool Item A B into center of sheave with A side toward sheave 8 Install nut C onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 9 Turn sheave counterclockwis...

Page 161: ...clutch cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod EBS DRIVEN BUSHING SERVICE EBS Driven Bushing Remo...

Page 162: ...be hot In order to avoid serious burns wear insulated gloves during the removal process 4 Flip sheave over onto puller 5 Install bushing tool Item 2 6 Install left hand nut C and spacer onto puller rod and 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 ...

Page 163: ... spring Install correct recommended shift weights 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 inspect driven clutch noting worn sheave bushing and ramp buttons and helix spring location Clean sheaves with denatured alcohol or brake cleaner install new ...

Page 164: ...h engagement Caution operator to operate machine within guidelines Vehicle operated with park brake on Inspect brake system Instruct firm effective use of throttle for efficient engage ment PVT noise Belt worn or separated thin spots loose belt Broken or worn clutch components cover hitting clutches Replace belt Inspect and repair as necessary Engagement erratic or stabby Thin spots on belt worn b...

Page 165: ...CLUTCH 6 34 NOTES ...

Page 166: ...0 AWD Front CV Joint Boot Replace 7 10 7 11 AWD Front Drive Axle Exploded View 7 12 AWD Strut Casting Seal Replacement 7 13 AWD Strut Seal Sleeve Replacement 7 13 7 14 AWD Front Prop Shaft Removal 7 14 U Joint Disassembly 7 15 U Joint Assembly 7 15 7 16 AWD Front Housing Removal 7 16 AWD Front Housing Disassembly 7 16 7 17 AWD Front Housing Assembly 7 17 7 18 AWD Front Housing Installation 7 18 AW...

Page 167: ...n 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 traction is regained the front wheels will overdrive the hub clutch pushing the clutch rollers 3 toward the lower part of the cam 5 disengaging the clutch The rollers are held in place by the spring 4 See Ill 2 The tension of ...

Page 168: ...move 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 catch pan beneath the front hub and remove the hub cap 5 Remove cotter pin and nut 6 Remove front hub and bearings HUB WHEEL BEARING INSTALLATION 1 Thoroughly inspect the hub internally If the hub bearing sleeve is damaged ...

Page 169: ...orque 18 ft lbs 25 Nm 5 Install cotter pin Bend each leg of cotter pin around castle nut in different directions NOTE If cotter pin hole does not align tighten slightly to align and install pin Do not exceed 144 in lbs 16 Nm 6 Reinstall hub cap 7 Remove fill check plug and rotate hole to either 4 00 or 8 00 position 8 Fill with Polaris Premium Demand Drive Hub Fluid until fluid trickles out NOTE D...

Page 170: ...ature Plate Brake Disc Bearing Race Bearing 1 000 I D Garter Spring Spacer Cotter Pin Washer Wheel Nut Refer to text on page 7 7 for more information Detail Front Hub Clutch Bearing 1 000 I D Use new cotter pin O Ring FINAL DRIVE 7 5 AWD FRONT HUB EXPLODED VIEW ...

Page 171: ...face CAUTION Do not use a hammer as damage to the seal will result 5 Thoroughly clean the brake disc with brake cleaner It is very important that the brake disc be free of any oil or solvents 6 Reinstall the brake disc using genuine Polaris OEM bolts that have a pre applied locking agent Do not substitute bolts or use old ones 7 Install attaching bolts and torque to 18 ft lbs 25 Nm MAGNETIC COIL R...

Page 172: ...Make sure the foam block is bonded well to protect the coil wires NOTE Coil wires must be contained in the brake line clip on the back side of the upper strut casting and the wires must be snug against the casting 5 6 Route the wires smoothly and away from any moving parts and secure in place with tie straps 6 7 Assemble front axle and connect hub wires HILLIARD CLUTCH DISASSEMBLY INSPECTION 1 Rem...

Page 173: ...urrent electro mechanical spring PN 3250032 wire diameter 018 46 mm spring free length end to end inside hooks 6 968 177 mm Measure wire diameter Measure free length to inside of loops as shown AWD ARMATURE PLATE INSPECTION Armature Plate Tabs Seal Sleeve 1 As the armature plate is engaged it should contact the outer magnet pole seal sleeve and the inner magnet pole Also the armature plate must be...

Page 174: ...ront hub and remove the hub cap 7 Remove cotter pin and nut 8 Remove hub bearings hilliard assembly and armature plat 9 Remove cotter pin and nut from lower A arm ball joint Remove lower A arm from ball joint 10 Using Roll Pin Remover PN 2872608 remove the roll pin at front housing Roller Pin Removal Tool PN 2872608 11 Remove the spindle and axle assembly from the strut casting bearing by pulling ...

Page 175: ...ground areas and splines of shaft are protected during handling to avoid damage S Do not allow boots to come into contact with sharp edges or hot engine and exhaust components S The driveshaft is not to be used as a lever arm to position other suspension components S Never use a hammer or sharp tools to remove or to install boot clamps S Be sure joints are thoroughly clean and that the proper amou...

Page 176: ... CV boot replacement requires 30g of grease If CV joint is cleaned an additional 30g of grease is required Refer to information below 8 Before installing the new boot remove all grease from the boot area and shaft NOTE It is very important to use the correct type and quantity of grease by using the grease contained in the boot kit DO NOT use a substitute grease and DO NOT overfill or underfill the...

Page 177: ...U 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 DRIVE 7 12 AWD FRONT DRIVE AXLE EXPLODED VIEW ...

Page 178: ...pin 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 FRONT HUB NOTE The front axle bearings have a larger I D 1 0625 than the hub bearings 1 000 Be sure to install the bearings with the larger I D in the strut housing and the bearings with the smaller...

Page 179: ...t 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 different positions around the pole assemblies The three measurements must be within 0005I 013 mm of each other If the gap is excessive the hubmay notengage Seal Sleeve Tool Step Use flat side to install sea...

Page 180: ...ort inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing caps 4 Force U joint cross to one side and lift out of inner yoke U JOINT ASSEMBLY 1 Install new bearing caps in yoke by hand Carefully install U joint cross with grease fitting properly positioned inward toward center of...

Page 181: ...to center the joint until it pivots freely in all directions 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 Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing...

Page 182: ...rew fill plug and remove pinion shaft assembly Inspect pinion gear for chipped broken or missing teeth NOTE Pinion shaft assembly will not clear the fill 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 pinion and output shaft bushings 4 Inspect bea...

Page 183: ...g and torque bolts to 14 ft lbs 19 Nm Pinion Shaft Lock Nut Torque 65 ft lbs 89 7 Nm Cover Bolts Torque 14 ft lbs 19 Nm Equal Shims 7 Install output shaft assembly NOTE The same shim thickness placed behind ring gear bearing must also be put behind the cover button 8 Install output shaft cover with new o ring and torque bolts to 14 ft lbs 19 Nm Cover Bolts Torque 14 ft lbs 19 Nm FRONT HOUSING INST...

Page 184: ...FINAL DRIVE 7 19 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 185: ...in 3 Loosen the hub retaining nut 4 Loosen the wheel nuts 5 Safely support the rear of the ATV CAUTION Serious injury could occur if machine tips or falls 6 Remove hub nut domed washer and flat washer 7 Remove wheel nuts and wheel 8 Remove hub 9 Remove upper control arm bolt as shown Remove Upper Control Arm Bolt ...

Page 186: ...ue 30 ft lbs 41 Nm Upper Control Arm Bolt Torque 35 ft lbs 48 Nm 4 Lift bearing carrier until top aligns with upper control arm Install and torque upper control arm bolt and torque to specification 5 Pull drive shaft outward and install hub onto driveshaft splines 6 Install cone washers with domed side facing outward 7 Install retainer nut wheel and wheel nuts 8 Remove jackstand and torque axle nu...

Page 187: ...e bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged REAR HUB ASSEMBLY 1 Support bottom of be...

Page 188: ...life S The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints S Over angling of joints beyond their capacity could result in boot or joint damage S Make sure surface ground areas and splines of shaft are protected during handling to avoid damage S Do not allow boots to come into contact with...

Page 189: ...upper control arm Torque bolt to 35 ft lbs 48 Nm 5 Install hub flat washer domed washer domed side out and nut Torque center nut to 100 ft lbs 138 Nm Install new cotter pin and hub cap 6 Install rear wheel and torque wheel nuts to specification Out Cone Washer Cone washer dome to outside 100 ft lbs 138 Nm Flat Washer Rear Hub Nut Torque 100 ft lbs 138 Nm Rear Wheel Nut Torque 20 ft lbs 27 Nm 7 Gre...

Page 190: ...inner hub to locate snap ring Snap ring located in recessed area Snap ring 3 Open the snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft with a soft faced hammer while holding snap ring open Tap CV Housing Off Shaft Spread ends of snap ring to remove joint from shaft 4 Place a new snap ring in the groove of the CV joint inner hub with tabs facing the shaft as s...

Page 191: ...of shaft See Page 7 25 2 Remove boot from shaft NOTE When replacing a damaged boot check the grease for contamination by rubbing it between two fingers A gritty feeling indicates contamination If the grease is not contaminated the boot can be replaced without cleaning the CV joint Use the recommended amount of grease for boot replacement only see below Proceed to Boot Installation CV JOINT CLEANIN...

Page 192: ...add the recommended amount of grease to the joint in addition to the grease pack supplied with boot kit NOTE CV Joint Grease Capacity Joint Capacity 50 Grams Boot Capacity 30 Grams Joint Capacity 50 Grams Boot Capacity 50 Grams INBOARD 100g Total OUTBOARD 80g Total CV Joint Grease 30g PN 1350046 50g PN 1350047 Outboard joint 30g if boot is replaced only Another 50g 80 total if joint is cleaned Inb...

Page 193: ...FINAL DRIVE 7 28 NOTES ...

Page 194: ... 2 Gear Shift Selector Disassembly 8 2 8 3 Gear Shift Selector Assembly 8 3 8 4 Gear Shift Selector Installation 8 4 Boot Replacement 8 4 Transmission Removal 8 5 8 6 Transmission Installation 8 6 8 7 Transmission Disassembly 8 8 8 13 Transmission Assembly 8 13 8 21 Troubleshooting 8 21 Transmission Exploded View 8 22 8 23 ...

Page 195: ...ts that interfere with access to shift selector seat right side panel and exhaust heat shield etc 2 Disconnect the two linkage rods from gear shift selector slides 3 Remove five bolts attaching gear shift selector to the mounting bracket 4 Lift gear selector out of mounting bracket and away from frame GEAR SHIFT SELECTOR DISASSEMBLY CAUTION Wear eye protection during this procedure Read each step ...

Page 196: ...els 8 Inspect O rings for damage Replace if any damage is found 9 Flush housing with parts washer fluid or penetrating oil to remove all moisture 10 Dry all gear shift selector parts and remove any corrosion with a wire brush Knob Screw Cap Clamp Boot Cover Apply Loctitet 515 Dowel Pin Handle Selector Slides Low 2 Short Notches High Reverse 1 Short 1 Long Notch Detent Spring Detent Bullet Centerin...

Page 197: ...ws to 12 ft lbs 17 Nm GEAR SHIFT SELECTOR INSTALLATION 1 Place gear shift selector back into the mounting bracket and replace five bolts 2 Reconnect linkage rods to gear shift selector slides Adjust as required See linkage adjustment procedures 3 Replace remaining parts BOOT REPLACEMENT NOTE If moisture is found in the gear shift selector the boot should be replaced Knob Screw Cap Clamp Boot Seal ...

Page 198: ... secure before beginning this service procedure Wear eye protection when removing and installing bearings and seals 5 Remove wheel nuts and wheels 6 Disconnect transmission shift linkage rods Remove right hand shock absorber 7 Disconnect harness from gear position switches 8 Remove right rear drive shaft see Chapter 7 Pull outward to remove from transmission 9 Disconnect the sway bar from both sid...

Page 199: ... All Season Grease PN 2871423 to splines of front output shaft install new O ring in prop shaft insert output shaft into prop shaft 2 Rotate transmission into place from right side of frame 3 Loosely install bottom transmission bolts Install bolts 4 Install lower right and left transmission mounting bolts front transmission bracket and rear stabilizer support bracket Tighten transmission bolts sec...

Page 200: ...ght hand shock absorbers 8 Apply brake and torque disc nut to 45 ft lbs 61 Nm 9 Install PVT system Refer to PVT section for procedure 10 Install airbox assembly and transmission vent line Be sure vent line is not kinked or pinched 11 Add Polaris Premium Synthetic Gearcase Lubricant to the proper level on dipstick Approximately 1 quart Do not overfill Premium Synthetic Gear Case Lubricant PN 287147...

Page 201: ...ion oil Drain 3 Remove all cover bolts Tap cover with soft face hammer to remove Note 2 bolts in center of cover Remove all bolts CAUTION Do not pry on case half sealing surfaces 4 Mark chain rotation direction for assembly Note location of chain tensioner cam If fully extended chain is worn beyond service limit Replace chain and chain tensioner shoe ...

Page 202: ...6 Remove rear output gear and chain as an assembly by lifting straight outward 7 Remove oil deflector Remove Screws 8 Make sure hole in oil deflector is clear and unobstructed Be sure hole is clear 9 Using a puller remove Hi Lo Reverse HLR shaft bearing and bearing thrust washer ...

Page 203: ...spect shift dogs for excessive rounding on the leading edges Replace if worn 12 Remove low range shift fork and dog Replace along with mating gear if wear is evident 13 Inspect face of shift fork for excessive wear discoloration or bending 14 Remove center shaft assembly by tapping on opposite side with a soft face hammer 15 Remove the remaining gears and shafts as an assembly Rotate the shift bel...

Page 204: ...en front output housing pinch bolts CAUTION Do not lose pinch plate Must be used for reassembly or transmission will be damaged Loosen Pinch Bolts Pinch Bolts 19 Mark housing and casting for reference upon reassembly 20 Using 2 1 8 Wrench PN 2871701 unscrew the front drive housing from the transmission casting until O ring is exposed 1 2 13mm NOTE Do not attempt to unscrew the front drive housing ...

Page 205: ...emove front output ring gear Inspect for broken chipped or worn teeth 25 Unscrew front drive housing and remove it from case Apply electrical tape to threads of housing to prevent damage 26 Using a brass hammer or a press drive the shaft bearing retaining ring and seal out of the housing from rear to front Bearing Shim s Seal Retaining Ring Shaft Housing 27 Slide seal off shaft and remove snap rin...

Page 206: ...g and plug using small end of bushing installation tool Center Drive Bushing Tool PN 2871697 2 Apply Loctite t 243 blue to threads of screws and install center shaft cover Tighten screws securely Shaft Bearing Plug FRONT OUTPUT HOUSING SNORKEL ASSEMBLY 1 Bearing is a light press fit on ring gear end of front output shaft Heat inner bearing on a hot plate or with a heat gun to ease installation Ins...

Page 207: ...easure shaft end play FRONT OUTPUT HOUSING SNORKEL INSTALLATION 6 Measured end play will be between 030 070 Shims must be added between bearing and circlip to reduce end play To calculate proper end play subtract total shim thickness from end play measured in Step 8 Add or subtract shims as required to obtain specified end play 000 003 Remove snap ring install shims reinstall snap ring It may be n...

Page 208: ... bolt to specification and bend lock plate against hexagonal portion of bolt Ring Gear Retaining Bolt 17 20 ft lbs 24 27 Nm Apply Loctitet 242 PN 2871949 10 Install pinion gear assembly and retaining plate Use Loctitet Primer N on threads and housing Apply Loctitet 242 PN 2871949 to bolts and torque to specification Pinion Gear Retainer Screws 17 20 ft lbs 24 27 Nm Apply Loctitet 242 PN 2871949 FR...

Page 209: ...ement point is 3 875 98 43mm from shaft centerline S Set backlash at 008 014 20 36mm S Check backlash in several locations of ring gear Front Gearcase Use This Mark Transmission Front Output Shaft Use This Mark 3 875 1 875 S Backlash Setting Tool PN 2871695 14 Install the Backlash Setting Tool PN 2871695 on shaft as shown With pinion gear held stationary rotate output shaft back and forth reading ...

Page 210: ... and grease Apply Crankcase Sealant PN 2871557 to mating surface of transmission case Install access plate with notch to front as shown torque screws to specification Access Plate Screws 8 10 ft lbs 11 14 Nm 17 Using the Magnum crankshaft installation tool lubricate and carefully install the front seal until flush with housing ...

Page 211: ... Needle Bearing Retaining Ring Retaining Ring Towards Gearcase 19 Stretch silent cluster chain tight 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 3 0904I Chain Stretch Limit 8 pitch length 3 0904I Maximum 20 Assemble the input shaft and Hi Low Reverse gear cluster as shown 21 The two shift forks can be easil...

Page 212: ...ft shaft 25 Lubricate and install inner thrust washer low gear and needle bearing 26 Install outer thrust washer and bearing 27 Install plastic oil deflector Apply Loctitet 242 PN 2871949 to screw threads Be sure deflector pin seats into case 28 Do not over tighten deflector screws or deflector may crack 29 Install drive gear with chain 30 Install chain tensioner Refer to Illustration on following...

Page 213: ...ll bearings with Polaris Premium Synthetic GearCase Lubricant PN 2871477 before installing cover 33 Place the bellcranks in neutral so shift fork shafts will engage into the spring loaded detents of case cover 34 Be sure sealing surfaces of cover and transmission case are clean Apply Crankcase Sealant PN 2871557 to surface of case and install cover bolts Torque to specification in three steps foll...

Page 214: ...sion 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 selector box S Worn rod ends clevis pins or pivot arm bushings S Linkage rod adjustment and rod end positioning S Shift selector rail travel S Worn broken or damaged internal transmission components NOTE To determine if shifting diff...

Page 215: ...7 29 18 77 13 28 76 75 72 2 16 21 35 33 38 30 22 39 23 31 34 19 5 3 9 10 11 1 17 6 12 1 14 74 15 37 36 20 55 54 40 41 32 78 73 4 56 53 57 52 51 50 49 48 47 46 59 61 60 64 63 62 65 66 45 68 69 27 26 70 25 71 24 42 67 43 44 58 47 5 32 33 33 32 30 29 28 28 ...

Page 216: ...rust 31 1 Gear 30T 32 3 Bearing Needle 33 3 Ring Retaining 34 1 Dog Engagement Low 35 1 Sprocket 24T 36 1 Shaft Reverse 29T 37 1 Dog Engagement Low 38 1 Gear 36T 39 1 Bearing Ball 40 1 Chain Silent 41 1 Shaft Input 42 8 Screw 43 1 Switch 2 Position 44 1 Vent Tube 45 1 Gearcase RH 46 2 Screw 47 4 Washer 48 1 Spacer 49 1 Screw 50 1 Washer Steel 51 1 Gear 31T 52 1 O Ring 53 1 Tube Snorkel 54 1 Spacer...

Page 217: ...TRANSMISSION 8 24 NOTES ...

Page 218: ...Change 9 7 9 8 Master Cylinder Removal 9 8 9 9 Master Cylinder Installation 9 9 Front Pad Removal 9 10 9 11 Front Pad Assembly 9 11 9 12 Brake Burnishing 9 12 Front Disc Inspection 9 12 Front Disc Removal Replacement 9 12 9 13 Front Caliper Removal 9 13 Front Caliper Disassembly 9 13 9 14 Front Caliper Inspection 9 14 9 15 Front Caliper Reassembly 9 15 Front Caliper Installation 9 16 Rear Pad Remo...

Page 219: ...R Frame Bushing Bushing Washer Washer Screw Spring Screw Rear Brake Master Cylinder Rear Brake Line Seal Bolt Brake Reservoir Clamp Reservoir Hose Brake Mount Master Cylinder Left Caliper Right Caliper Cross Fitting Brake Switch Rear Caliper Rear Brake Reservoir Top View ...

Page 220: ... ft lbs 22 25 Nm Torque O rings Washers Rear Caliper Seals Slide Pins Torque 30 35 ft lbs 41 48 Nm Piston Bushings Seal Bracket Pads Front Caliper O ring FRONT BRAKE CALIPER EXPLODED VIEW Caliper Mount Piston Bushing Boot Square O Rings Socket Set Screw Boot Bushing Brake Pads Caliper Assembly Bleeder Screw ...

Page 221: ...6 4 750mm 167 4 242mm 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 Item Torque ft lbs except where noted Torque Nm Front Caliper Mounting Bolts 16 0 22 Output Shaft Caliper Mounting Bolts 15 0 21 Master Cylinder Mounting Bolts 25 in lbs 3 0 Master Cylinder Reservoir Cover...

Page 222: ...vibration If cleaning does not reduce the occurrence of brake noise Permatext Disc Brake Quiet PN 2872113 can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Brake Noise Troubleshooting Possible Cause Remedy Dirt dust or im bedded material on pads or disc Spray disc and p...

Page 223: ...pensates for fluid expansion heated fluid or contraction cooled fluid During system service be sure this port is open Due to the high temperatures created within the system during heavy braking it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion Never overfill the reservoir Fill to 1 4 5 16 64 80 cm from top of the cylinder This system also inco...

Page 224: ...d be used to change fluid or bleed brakes during regular maintenance 1 Clean reservoir cover thoroughly 2 Remove screws cover and diaphragm C from reservoir 3 Inspect vent slots A in cover and remove any debris or blockage B A D C Sight Glass 4 If changing fluid remove old fluid from reservoir with a Mity Vact pump or similar tool Mity Vact PN 2870975 5 Add brake fluid to the indicated MAX level i...

Page 225: ...10 Tighten bleeder screw securely and remove bleeder hose Torque the bleeder screw to 25 30 in lbs 2 80 3 40 Nm 11 Repeat procedure Steps 5 9 for the remaining caliper s 12 Add Polaris Dot 3 Brake Fluid PN 2870990 to MAX level inside reservoir Master Cylinder Fluid Level MAX level inside reservoir Sight glass must look dark if sight glass is clear fluid level is too low 13 Install diaphragm cover ...

Page 226: ...t 1 Install master cylinder on handlebars Torque mounting bolts to 25 in lbs 3 Nm Torque the inside bolt first as indicated in the illustration to the right Torque both bolts to 25 in lbs 3 Nm Torque this bolt first NOTE To speed up the brake bleeding procedure the master cylinder can be purged of air before brake line is attached Fill with DOT3 Brake Fluid PN 2870990 and pump lever slowly two to ...

Page 227: ...m mounting bracket 4 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 when piston is pushed back into caliper Remove excess fluid from reservoir as required 5 Push mounting bracket inward and slip outer brake pad past edge Remove inner pad 6 Measure the t...

Page 228: ...871423 2 Compress 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 torque mounting bolts 18 ft lbs 25 Nm Front Caliper Mounting Bolts Torque 18 ft lbs 25Nm 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 12 7 mm of ...

Page 229: ...edure Do not allow pads or disc to become hot or warpage may result Repeat this procedure 10 times FRONT DISC INSPECTION 1 Visually inspect the 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 Disc Thickness Service Limit 140 3 556 mm New 150 164 3 81...

Page 230: ...ing bolts The bolts have a pre applied locking agent which is destroyed upon removal FRONT CALIPER REMOVAL CAUTION Use care when supporting 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 10 2 Using a line wrench loosen and remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 3 R...

Page 231: ...eal grooves in caliper body Clean Components FRONT CALIPER INSPECTION 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare tospecifications Replace 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 Measure diameter and replace ...

Page 232: ...PN 2870990 C Install piston D with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins with Polaris Premium All Season Grease and install the rubber dust seal boots Polaris Premium All Season Grease PN 2871423 4 Compress the mounting bracket and make sure the dust seals are fully seated Install the pads ...

Page 233: ...olt Torque 18 ft lbs 25 Nm 2 Install brake line and tighten securely with a line wrench 3 Install the adjuster screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow brake bleeding procedure outlined on Pages 9 7 9 8 5 Install wheels and torque wheel nuts to specification Front Wheel Nut Torque 20 ft lbs 27 Nm ...

Page 234: ...the machine Remove the rear tire 2 Remove caliper mounting bolts and lift 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 3 Push caliper pistons into caliper bore slowly with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back ...

Page 235: ... Nm 48 Nm Caliper Slide Pin Torque 30 35 ft lbs 41 Nm 48 Nm Torque Slide Pin 4 Install caliper and torque the mounting bolts Torque Mounting Bolts Rear Brake Caliper Torque 18 ft lbs 25 Nm 5 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the master cylinder 6 It is recommended that a burnishing...

Page 236: ... the brake pads D A Caliper B C D 5 Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers Seal Piston O rings Caliper Anvil Bolts 6 Remove seals and O rings Clean the O ring grooves 7 Clean disc caliper body and pistons with brake cleaner or alcohol 8 Remove the slide bolt bushings Inspect the bushings and O rings and replace if necessary Bushing O ring 9 Inspect...

Page 237: ... sure O rings are properly positioned in groove Tighten the caliper anvil bolts and then torque the anvil bolts evenly to 16 18 ft lbs 22 25 Nm Caliper Anvil Bolt Torque 16 18 ft lbs 22 Nm 25 Nm 3 Install brake pads in caliper body with friction material facing each other Install the slide pins and the slide pin retaining ring Torque the slide pins to 30 35 ft lbs 41 48 Nm Caliper Slide Pin Torque...

Page 238: ...ance Service Limit 002 051 mm difference between measurements 3 Mount dial indicator and measure disc runout Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 005 127 mm TROUBLESHOOTING Brakes Squeal G Dirty contaminated friction pads G Improper alignment G Worn disc G Worn disc splines Poor Brake Performance G Air in system G Water in system brake fluid contaminate...

Page 239: ...BRAKES 9 22 ...

Page 240: ...ch Test 10 11 10 12 Electronic Throttle Circuit System Operation 10 12 Ignition System Testing Flow Chart 10 13 Ignition System Troubleshooting 10 14 CDI Output Tests 10 14 Charging System Testing 10 14 10 16 Battery Activation Service 10 17 10 20 Head Light Brake Light Lamp Service 10 20 10 22 Starter System Testing 10 22 Starter System Troubleshooting 10 22 10 23 Starter Motor Service 10 22 10 2...

Page 241: ...nt readings Refer to the Owner s manual included with your meter for more information GVoltage amperage and resistance values included in this manual are obtained with a Fluket 77 Digital Multimeter PV 43568 This meter is 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...

Page 242: ... TIMING DEGREES B T D C MAXIMUM ADVANCE POINT 0 1000 2500 3000 3500 4000 4500 5000 TYPICAL IGNITION TIMING CURVE ACTUAL ADVANCE POINT MAY VARY BY SEVERAL HUNDRED RPM ABOVE OR BELOW 5000 USE THE POINT OF MAXIMUM ADVANCE WHEN CHECKING IGNITION TIMIN Retard Advance Rotation GEAR POSITION INDICATOR SWITCH TEST High Range Neutral Reverse F F F F Low Range D C B A C B A D F F F F F F F F F F F F High Ne...

Page 243: ...al hours the engine has been in operation Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and their dealer with a convenient way to schedule routine maintenance When the ATV leaves the factory this feature is turned OFF You must enable this feature if you intend to use it to track maintenance requirements Low Oil Pressure Indicates that the...

Page 244: ...tes that you are between gears It can also indicate that the trans mission switch is broken StAtr Stator is displayed when the gauge senses ground speed but no engine rpm for at least 10 seconds May in dicate a failing stator or wir ing problem hdLbr Handlebar is displayed when the mode override but ton is stuck in for more than ten seconds in any mode ex cept Programmable Service Interval or Diag...

Page 245: ... Spray 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 is fully installed and that the indexing key is in the headlight pod keyway 3 Hold the pod assembly securely and insert the instrument cluster into the pod assembly Twist the instrument cluste...

Page 246: ...CONNECT CLUSTER LEAVE HEADLIGHT POD DISASSEMBLED SHIFT TO LOW OR HIGH LEAVE AWD ON Y REMOVE THROTTLE CONTROL COVER CHECK FOR CONTINUITY ACROSS AWD INDICATOR BULB Y REPLACE INSTRUMENT CLUSTER BAD AWD BULB PROCEED TO IF AWD PROBLEM PERSISTS MECHANICAL AWD COMPONENTS N 1 Red 12V Constant 2 Red White 12V Switched 3 Grey Orange Mode Override button 4 Black Ignition Kill 5 N C 6 N C 7 Yellow Red RPM Inp...

Page 247: ...erride button 4 Black Ignition Kill 5 N C 6 N C 7 Yellow Red RPM Input 8 Brown Ground 9 Blue White Engine Overheat Switch 10 Purple Yellow Oil Pressure Switch 11 Orange Red Park Gear 12 Purple Reverse Gear 13 Green White Neutral 14 White Blue Low Gear 15 Blue Red High Gear 16 Brown White AWD Control 16 Pin Connector TEST 3 NO REVERSE SPEED LIMIT IS THE SPEEDO READ OUT CHECK SPEEDOMETER PERFORM TES...

Page 248: ...ORT CIRCUITS TO GROUND DISCONNECT CONNECTOR MEASURE BETWEEN HUB COIL BROWN WHT GROUND REPAIR HUB COIL WIRING REPLACE SPEEDOMETER NO PROBLEM N N Y Y Y 1 Red 12V Constant 2 Red White 12V Switched 3 Grey Orange Mode Override button 4 Black Ignition Kill 5 N C 6 N C 7 Yellow Red RPM Input 8 Brown Ground 9 Blue White Engine Overheat Switch 10 Purple Yellow OIl Pressure Switch 11 Orange Red Park Gear 12...

Page 249: ... jumper leads 3 Elevate front right side of vehicle until tire is off the ground 4 Slowly turn right front wheel while observing the test light 5 If light flashes sensor is O K Be sure connections are good and 9 volt battery is in good condition 9V Static Timing Light Harness LED Brn To Sensor Red To Sensor White To Sensor Black 680W Wht Blk START HERE PN 2871745 Y N CLUSTER NOTE OVERRIDE SWITCH P...

Page 250: ...the fan switch reaches the specified temperature it becomes conductive and sends power to the fan motor through to the Orange Black wire The ground path for the fan motor is through the Brown harness wire CAUTION Keep hands away from fan blades during this procedure Serious personal injury could result NOTE The fan switch may not function or operation may be delayed if coolant level is low or if a...

Page 251: ...sition contacts are separated as shown below by throttle cable tension The contacts are open during normal operation regardless of throttle lever position In the event of a mechanical problem in the throttle mechanism cable tension is lost the switch contacts close connecting the CDI black wire to ground which prevents ignition spark This is the same as turning the key or engine stop switch OFF Te...

Page 252: ...ount using an ohmmeter The coil mount 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 Wire Tab to Ground on coil mount or engine 3 to 5 Ohms Secondary Side High Tension Wire to High Ten sion Wire Cap installed 11 300 Cap removed 6300 Are these values within specs Replace the ignitio...

Page 253: ...TH PEAK READING VOLTMETER The following peak voltage tests will measure the amount of output directly from each component A peak reading voltmeter must be used to perform the tests A variety of peak reading adaptors are commercially available for use with the Fluke t 77 Digital Multitester PV 43568 and other digital VOMs which will allow peak voltage tests to be performed accurately Follow the dir...

Page 254: ...and start the engine With the engine running at idle disconnect the negative cable from the battery post without disturbing the meter leads Observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the battery starts to charge ammeter indication is positive 7 With lights and other electrical load off the break even point should occur at approximately 1...

Page 255: ...regulator 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 tests indicate a good condition but the charging voltage does not rise above battery voltage at the connector or wire harness replace the volt age regulator No Yes No Yes Perform system Break Even A...

Page 256: ...olyte after a battery has been in service NOTE New Battery Battery must be fully charged before use or battery life will be significantly reduced 10 30 of the battery s full potential To activate a new battery 1 Remove vent plug from vent fitting Remove cell caps 2 Fill battery with electrolyte to upper level marks on case 3 Set battery aside to allow for acid absorption and stabilization for 30 m...

Page 257: ...er a service complaint is related to either the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test OCV OPEN CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester Readings of 12 6 volts or less require further battery testi...

Page 258: ...nd wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning NOTE Do not get any of the baking soda into the battery or the acid will be neutralized GUsing a wire brush or knife remove any corrosion from the cables and terminals GMake sure that the electrolyte is at the proper level Add distilled water if necessary GCharge at a rate ...

Page 259: ...ve headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be included on the seat On machines with separate low beam lights the drop should be 8 20 3 cm in 25 from the center of the low beam lamp 5 Adjust beam to desired position HIGH BEAM HEADLIGHT LAMP REPLACEMENT CAUTION Do not service while headlight...

Page 260: ...usting knob 5 1 8 13 cm Distance from headlamp parting line to end of adjustment knob stop is 5 1 8 13 cm TAILLIGHT BRAKELIGHT LAMP REPLACEMENT If the taillight brakelight does not work the lamp may need to be replaced Lens Cover Bulb 1 From the rear of the taillight remove two screws holding lens cover in place and remove lens cover 2 Remove lamp and replace it with recommended lamp Apply Nyogelt...

Page 261: ...er motor GAutomatic compression release inoperative Starter Motor Turns Engine Does Not Rotate GFaulty starter drive GFaulty starter drive gears or starter motor gear GFaulty flywheel gear or loose flywheel VOLTAGE DROP TEST The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connect...

Page 262: ...3 ohms or less Measure the resistance between the cable terminal and brush housing Make sure the brush is not touching the case The reading should be infinite 2 Remove nut flat washer large phenolic washer two small phenolic washers and O Ring from brush terminal Inspect the O Ring and replace if damaged Brush Length 5 16 8 cm Brush Length Service Limit 5 16 8 cm 3 Remove brush plate and brushes M...

Page 263: ...e from starter casing Note order of shims on drive end for reassembly 2 Inspect surface of commutator Replace if excessively worn or damaged 3 Using a digital multitester measure the resistance between each of the commutator segments The reading should be 3 ohms or less 4 Measure the resistance between each commutator segment and the armature shaft The reading should be infinite no continuity 5 Ch...

Page 264: ...back brushes while installing shaft in bushing 6 Reinstall starter motor housing bolts Make sure O Rings are in good condition and seated in groove 7 Inspect permanent magnets in starter housing Make sure they are not cracked or separated from housing CAUTION Use care when handling starter housing Do not drop or strike the housing as magnet damage is possible If magnets are damaged starter must be...

Page 265: ...onnect the solenoid Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery to solenoid wire De press starter button Reading should be less than 1 V D C Clean the battery to solenoid cable ends or replace the cable Connect the black tester lead to solenoid end of battery to solenoid cable Connect red tester lead to solenoid end of solenoid to start...

Page 266: ...RING DIAGRAM 2003 SPORTSMAN 400 EARLY BUILD A IF THE CONNECTOR IN LOCATION A LOCATED ON TOP OF ENGINE IS AN EIGHT PIN CONNECTOR NOT USE THE SPORTSMAN 400 LATE BUILD SCHEMATIC ON PAGE 10 28 LIKE THE CONNECTOR IN LOCATION A ...

Page 267: ... 28 WIRING DIAGRAM 2003 SPORTSMAN 400 LATE BUILD 500 A A IF THE CONNECTOR IS A MOLDED 3 PIN CONNECTOR NOT LIKE CONNECTOR BUILD SCHEMATIC ON PAGE 10 27 LOCATED TOP OF ENGINE SPARK PLUG A BELOW USE SPORTSMAN 400 EARLY ...

Page 268: ...ke Pad Inspection 2 28 Brake Pad Installation Rear 9 18 Brake Pad Removal Front 9 10 Brake Pad Removal Rear 9 17 9 18 Brake System Inspection 2 28 Brake System Main Components 9 2 Brake System Operation 9 6 Brake Auxiliary Hydraulic 2 29 Brake Auxiliary Testing 2 28 Brakelight Lamp Replacement 10 21 Breather Filter Maintenance 2 20 Breather Hose Inspection 2 20 C Cam Chain Drive Sprocket Installat...

Page 269: ...spection 3 21 Cylinder Head Installation 3 46 Cylinder Head Reconditioning 3 23 Cylinder Head Removal 3 19 3 20 Cylinder Head Warpage 3 21 Cylinder Honing 3 8 Cylinder Inspection 3 29 Cylinder Installation 3 45 Cylinder Removal Inspection 3 27 D Decal Replacement 5 11 Decimal Equivalent Chart 1 10 Diagnostic Mode 10 4 10 5 Draining Recoil Housing 2 20 Drive Belt Installation 6 15 Drive Belt Remova...

Page 270: ...al Sleeve Replacement 7 13 Front Drive Axle Exploded View 7 12 Front Hub Bearing Adjustment AWD 7 4 Front Hub Disassembly 7 3 Front Hub Exploded View AWD 7 5 Front Hub Fluid Change 2 27 Front Hub Fluid Level Inspection 2 26 Front Hub Seal Replacement AWD 7 6 Front Hub Wheel Bearing Installation 7 3 Front Prop Shaft Removal 7 14 Front Strut Assembly 5 9 Front Strut Ball Joint Replacement 5 10 Front...

Page 271: ... Pump Priming Magnum 500 2 22 Oil Pump Removal Inspection 3 34 Oil Pump Shaft End Play 3 40 One Way Valve 3 33 One Way Valve Installation 3 43 Output Housing Snorkel Assembly 8 13 8 14 Output Housing Snorkel Backlash Adjustment 8 15 8 16 P Pilot Screw Adjustment 2 12 Piston Identification 3 5 Piston Installation 3 44 Piston Removal 3 28 Piston Ring Installation 3 44 Piston Ring Installed Gap 3 31 ...

Page 272: ...ension 5 2 Specifications Torque Transmission 8 2 Speedometer Installation 10 6 Speedometer Troubleshooting 10 7 10 8 10 9 10 10 10 11 Speedometer Removal 10 6 Speedometer Odometer 10 4 Spider Removal 6 11 Starter Assembly 10 25 Starter Disassembly 10 22 Starter Drive 10 25 Starter Drive Installation 3 50 Starter Drive Removal Inspection 3 31 Starter Motor Armature Testing 10 24 Starter Motor Brus...

Page 273: ...version Table 1 11 V Valve Clearance 2 23 Valve Guide Removal Installation 3 23 Valve Inspection 3 22 Valve Seal Testing 3 26 Valve Seat Inspection 3 23 Valve Seat Reconditioning 3 23 Vent Line Maintenance 2 14 VIN Identification 1 2 Voltage Drop Test 10 22 Voltage Test Open Circuit 10 18 W Warning Indications for Rider Information Center 10 5 Water Pump Mechanical Seal Installation 3 42 Water Pum...

Page 274: ...PN 9918065 Printed in USA ...

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