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Polaris SPORTSMAN 600 2003 Service Manual Download Page 216

BRAKES

9.12

FRONT CALIPER
INSPECTION

1.

Inspect caliper body for nicks, scratches or wear.
Measure bore size and compare to specifications.
Replace if damage is evident or if worn beyond
service limit.

Front Caliper Piston Bore I.D.

Std. 1.191-1.192

²

(30.25-30.28 mm)

Service Limit 1.193

²

(30.30 mm)

2.

Inspect piston for nicks, scratches, wear or
damage.

Measure diameter and replace if

damaged or worn beyond service limit.

3.

Inspect the brake disc and pads as outlined for
brake pad replacement this section. See Pages
9.10--9.11.

FRONT CALIPER REASSEMBLY

1.

Install new O-rings (A) in the caliper body (B). Be
sure groove is clean and free of residue or brakes
may drag upon assembly.

A

B

C

D

2.

Coat piston with clean Polaris DOT 3 Brake Fluid
(C). Install piston (D) with a twisting motion while
pushing inward. Piston should slide in and out of
bore smoothly, with light resistance.

3.

Lubricate 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 as
shown on Page 9.10. Clean the disc and pads
with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease.

Enfocus Software - Customer Support

Summary of Contents for SPORTSMAN 600 2003

Page 1: ...2003 SPORTSMAN 600 2002 2003 SPORTSMAN 700 SERVICE MANUAL PN 9918066 ...

Page 2: ...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 3: ...erations component identification and unit repair along with service specifications for 2003 Polaris Sportsman 600 700 ATVs Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2002 Sportsman 600 700 ATV Service Manual PN 9918066 ECopyright 2002 Polaris Sales Inc All information contained within this publication...

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: ...mensions 1 4 1 5 Specifications 2002 Sportsman 700 1 6 1 7 Specifications 2003 Sportsman 600 1 8 1 9 Specifications 2003 Sportsman 700 1 10 1 11 Publication Numbers 1 12 Paint Codes 1 12 Replacement Keys 1 12 Standard Torque Specifications 1 13 Decimal Equivalent Chart 1 14 Conversion Table 1 15 Tap Drill Charts 1 16 Glossary of Terms 1 17 1 18 ...

Page 6: ...Engine Emissions Model Year Plant 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 top side of the crankcase A An additional number is stamped on the side o...

Page 7: ...SPORTSMAN 600 SPORTSMAN 700 NOTE MODELS WILL VARY IN COLOR GENERAL INFORMATION GENERAL INFORMATION 1 3 2003 SPRORTSMAN 600 700 MODELS ...

Page 8: ...46 in 116 84 cm 85 in 215 90 cm 50 75 in 128 90 cm FRONT SIDE GENERAL INFORMATION 1 4 MACHINE DIMENSIONS ...

Page 9: ...46 in 116 84 cm 47 in 119 38 cm 11 in 27 94 cm 46 in 116 84 cm REAR GENERAL INFORMATION GENERAL INFORMATION 1 5 MACHINE DIMENSIONS ...

Page 10: ...w EBS 1800 3700 6000 12000 20 54 Blue Green 5631214 White Yellow EBS ENGINE Type 4 Cycle Twin Cyl Displacement 683 cc Bore 3 149I 80 mm Stroke 2 677I 68 mm Valve Clearance In Ex 0 006 0 006I TDC on compression Compression Ratio 9 78 1 Full Stroke Cooling Liquid Lubrication Type Pressurized Wet Sump Operating RPM 200 6000 RPM Idle RPM 200 lights off 1100 RPM Compression Pressure Std 15 CARBURETION ...

Page 11: ... Engine Lubricant PDD Premium Demand Drive Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV 4 Wheel Independent Shaft Drive Front Suspension MacPherson Strut Gear Reduction Low 7 5 1 Tow Capacity 1225 lbs 555 6 kg Gear Reduction Rev 5 11 1 Turning Radius 76I 181 61 cm Gear Reduction High 3 09 1 Toe Out 1 8I 1 4I 3 6 35 mm Front Drive Ratio 3 82 1 Ground Clearance 11I 27 94 cm Final Drive...

Page 12: ...low EBS 1800 3700 6000 12000 10 WH Blue Green 5631214 White Yellow EBS ENGINE Type 4 Cycle Twin Cyl Displacement 597 cc Bore 3 012I 76 5 mm Stroke 2 559I 65 mm Compression Ratio 9 35 1 Full Stroke Cooling Liquid Lubrication Type Pressurized Wet Sump Operating RPMr200 6000 RPM Idle RPM r 100 lights off 1100 RPM Compression Pressure 150 170psi r15 CARBURETION Type BST 34 Mikuni Main Jet 155 Pilot Je...

Page 13: ...emium Demand Drive Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV 4 Wheel Independent Shaft Drive Front Suspension MacPherson Strut Gear Reduction Low 7 49 1 Tow Capacity 1225 lbs 555 6 kg Gear Reduction Rev 5 11 1 Turning Radius 76I 181 61 cm Gear Reduction High 2 89 1 Toe Out 1 8I 1 4I 3 6 35 mm Front Drive Ratio 3 82 1 Ground Clearance 11I 27 94 cm Final Drive Ratio 3 10 1 Front Ver...

Page 14: ...llow EBS 1800 3700 6000 12000 20 54 Blue Green 5631214 White Yellow EBS ENGINE Type 4 Cycle Twin Cyl Displacement 683 cc Bore 3 149I 80 mm Stroke 2 677I 68 mm Compression Ratio 9 78 1 Full Stroke Cooling Liquid Lubrication Type Pressurized Wet Sump Operating RPMr200 6000 RPM Idle RPMr100 lights off 1100 RPM Compression Pressure 150 170psi r15 CARBURETION Type BST 34 Mikuni Main Jet 155 Pilot Jet 4...

Page 15: ...ricant PDD Premium Demand Drive Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV 4 Wheel Independent Shaft Drive Front Suspension MacPherson Strut Gear Reduction Low 7 49 1 Tow Capacity 1225 lbs 555 6 kg Gear Reduction Rev 5 1 1 Turning Radius 76I 181 61 cm Gear Reduction High 2 89 1 Toe Out 1 8I 1 4I 3 6 35 mm Front Drive Ratio 3 82 1 Ground Clearance 11I 27 94 cm Final Drive Ratio 3 10...

Page 16: ... 067 FRAME COLOR All P067 Medium Gloss Black 9440 8520147 Order direct from Midwest Industrial Coatings 952 942 1840 Mix as directed 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 Should both keys become lost ignition switch replaceme...

Page 17: ...bs Nm 10 24 27 3 1 43 5 0 60 6 9 10 32 31 3 6 49 5 6 68 7 8 Torque ft lbs Nm 1 4 20 5 7 8 11 12 16 1 4 28 6 8 10 14 14 19 5 16 18 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 f...

Page 18: ...75 25 64 3906 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 6...

Page 19: ...eters cc Cubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 Liters l Liters l x 1 057 US quarts US qt US gallons US gal x 3 785 L...

Page 20: ...1 1 8 7 63 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...

Page 21: ... dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase Measure at various points especially at PTO end 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 S...

Page 22: ... increases 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 Usuall...

Page 23: ...pection 2 11 Carburetor Adjustments 2 12 2 13 Fuel System 2 13 2 14 Compression Test 2 14 2 15 Battery Maintenance 2 15 2 16 Electrical 2 16 Coolant System Maintenance 2 17 2 18 Radiator Screen Removal 2 18 Air Filter Service 2 19 Air Box Sediment Tube Service 2 19 Breather Filter 2 20 PVT Drying PVT Drain Plug 2 20 Oil Change Filter 2 21 2 22 Steering and Toe Alignment 2 22 2 25 Exhaust System Ma...

Page 24: ...Daily Drain deposits whenever visible Engine Breather Filter 20 hrs Monthly 200 320 Inspect and replace if necessary E Idle Speed As required As required Adjust as required 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 Lubricate Replace if necessary Carburetor Float Bowl 50 hrs 6 months ...

Page 25: ...nspect 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 System Pre ride Pre ride Pre Ride Inspection Item Wheels Pre ride Pre ride Pre Ride Inspection Item Frame Nuts Bolts Fasteners Pre ride ...

Page 26: ...utlined in this chapter 2 9 Coolant Level Polaris Premium 60 40 Pre mixed Antifreeze Coolant or a 50 50 mixture high quality antifreeze coolant and distilled water Allow engine and cooling system to cool completely and check level in ra diator Fill to top of filler neck If reser voir was empty or extremely low fill reservoir tank to full line if necessary 2 18 Brake Fluid Polaris DOT 3 Brake Fluid...

Page 27: ...z 10 Count 2871312 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 Threa...

Page 28: ...4 Carburetor Float Adjustment Tool 4 2870871 Ball Joint Replacement Tool 5 2870623 Shock Absorber Spring Compression Tool 5 2871572 Strut Rod Wrench 5 2871573 LH Strut Spring Compressor 5 2871574 RH Strut Spring Compressor 5 7052069 Charging Needle 5 2200421 Gas Shock Recharging Kit 5 2871352 Shock Rod Holding Tool 5 2871351 Foxt Shock IFP Depth Tool 5 2870506 Clutch Puller 6 9314177 Clutch Holdin...

Page 29: ...ick and add to proper level Change after 1st month 6 months or 100 hours thereafter Change more often 25 50 hours in extremely dirty condi tions or short trip cold weather operation 2 Transmis sion Polaris Synthetic Gear Case Lubricant Add lube to bottom of fill hole Change annually 3 Front Gear Case Premium Demand Drive Hub Fluid Drain completely Add lube to spe cified quantity Change annually 4 ...

Page 30: ...se Locate fittings and grease Semi annually 9 Front Hub strut Polaris All Season Grease Locate fittings and grease Semi 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 or hauling heavy loads Annually or 100 hours ...

Page 31: ...ough the skid plate Catch and discard used oil properly 2 Clean and reinstall drain plug using a new sealing washer 3 Remove fill plug 4 Add proper amount of lubricant Front Gearcase Fill with the recommended fluid amount or fill to 0 75 in 19 mm below the threads of the fill plug See ILL 1 ILL 2 Rear Gearcase Fill with the recommended fluid amount or fill to the bottom of the fill plug hole threa...

Page 32: ...fill hole as shown at right To change lubricant 1 Remove propshaft shield from the right side of the vehicle 2 Remove transmission drain plug to drain the oil Catch and discard used oil properly 3 Clean and reinstall the drain plug with a new sealing washer Torque to specification 4 Remove fill plug 5 Add Polaris Premium Synthetic Gearcase Lubricant to proper level as described above 6 Check for l...

Page 33: ...m full right to full left If idle speed increases at any point in the turning range inspect throttle cable routing and condition Adjust cable tension as needed until lock to lock turning can be accomplished with no rise in engine rpm 5 Replace the throttle cable if worn kinked or damaged To remove the ETC cover 1 Use a medium flat blade screwdriver and insert blade into the pocket of the cover sta...

Page 34: ...lways 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 until idle RPM begins to drop 7 Center the pilot screw between the points in Step 5 and 6 8 Re ad...

Page 35: ...is extremely flammable and explosive under certain conditions G Always stop the engine and refuel outdoors or in a well ventilated area G Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored G Do not overfill the tank Do not fill the tank neck G If you get gasoline in your eyes or if you swallow gasoline seek medical attention imm...

Page 36: ...E 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 clean container beneath the bowl drain spigot or bowl drain hose 3 Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely 4 Inspect the drained fuel for water or sediment 5 Tighten drain screw 6 Turn fuel valve to ON 7 Start machine ...

Page 37: ...ies of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician im mediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Venti late when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE New Batteries B...

Page 38: ...sure it is properly routed and not kinked or pinched 10 Coat terminals and bolt threads with Dielectric Grease PN 2871329 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 ...

Page 39: ...E Test the strength of the coolant using an antifreeze hydrometer Antifreeze Hydrometer G A 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection G Do not use tap water Tap water contains minerals and impurities which build up in the system Do not add straight antifreeze or straight water to the system Straight wate...

Page 40: ...R COOLANT LEVEL INSPECTION WARNING Never remove the radiator pressure cap when the engine is warm or hot Escaping steam and fluid can cause severe burns The engine must be allowed to cool before removing the pressure cap 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 t...

Page 41: ...r tears or damage 8 Apply foam filter oil or clean engine oil and squeeze until excess oil is removed 9 Inspect main filter and replace if necessary If the 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 ...

Page 42: ...e the engine without the pre filter BREATHER HOSE 1 Be sure breather line is routed properly and secured in place CAUTION Make sure lines are not kinked or pinched PVT DRYING PVT DRAIN PLUG NOTE If operating the ATV in or through water be sure to check the PVT cover and other components for water ingestion The ATV should be checked immediately 1 To release any water that maybe trapped in the PVT c...

Page 43: ...See NOTE below NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Proper level indication is determined on the upper surface of the dipstick as it is being removed regardless of the level marks being on top or on bottom See the next illustration Always read top side of dipstick to properly check oil level in crankcase Dipstick ...

Page 44: ...Range 40 F to 120 F Crankcase Drain Plug Torque 20 22 ft lbs 27 30 Nm Oil Filter Torque Turn by hand until filter gasket contacts sealing surface then turn an additional 1 2 turn Oil Filter Wrench PV 43527 13 Place gear selector in neutral and set parking brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick...

Page 45: ...or movement G Repeat inspection for inner tie rod end on steering post G Replace any worn steering components Steering should move freely through entire range of travel without binding G Elevate front end of machine so front wheels are off the ground Check for any looseness in front hub wheel assembly by grasping the tire firmly at top and bottom first and then at front and rear Try to move the wh...

Page 46: ...ch 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 rim ...

Page 47: ...is 1 8 to 1 4 3 to 6 cm toe out This means the measurement at the front of the tire A is 1 8 to 1 4 3 to 6 cm wider than the measurement at the rear B Chalk Line Measurement A Measurement B Ill 1 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 ahea...

Page 48: ...veral more times 4 If particles are still suspected to be in the muffler back the machine onto an incline so the rear of the machine is one foot higher than the front Set the hand brake and block the wheels Make sure the 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 i...

Page 49: ... on the footrest Auxiliary Foot Brake Pedal Floor Board Surface Full Height Full Engagement AUXILIARY BRAKE ADJUSTMENT HYDRAULIC Use the following procedure to inspect the hydraulic auxiliary foot brake system and adjust or bleed if necessary First check foot brake effectiveness by applying 50lb approx downward force on the pedal The top of the pedal should be at least 1 inch 25 4mm above the surf...

Page 50: ...ge G Inspect shock for leakage CONTROLS Check controls for proper operation positioning and adjustment Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body WHEELS Inspect all wheels for runout or damage Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts Apply Loctitet 271 PN 2871954 to the wheel...

Page 51: ...ION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle Tire Pressure Inspection PSI Cold Front Rear 5 5 TIRE INSPECTION G Improper tire inflation may affect ATV maneuverability G When replacing a tire always use original equipment size and type G The use of non standard size or type tires may affect ATV handling Tire Tread Depth Always replace tires when ...

Page 52: ...MAINTENANCE MAINTENANCE 2 30 ...

Page 53: ... 21 Valve Inspection 3 22 Combustion Chamber 3 22 Valve Seat Reconditioning 3 23 3 25 Cylinder Head Assembly 3 25 Valve Sealing Test 3 26 Valve Train Exploded View 3 26 Engine Head Reassembly 3 27 3 29 Cylinder Removal 3 29 Valve Lifter Removal Inspection 3 29 Piston Removal 3 29 3 30 Cylinder Inspection 3 30 3 31 Piston Rod Ring Service 3 31 3 33 Starter Bendix Removal Inspection 3 33 3 34 Flywhe...

Page 54: ...crews Magnetic Plug Gear Stator Housing Cover Journal Bearings Baffle Oil Pickup Seal Bearing Bushing Bearing Oil Dipstick 20 24 ft lbs 27 33 Nm O Ring Assembly Seals Apply Loctitet 242 to the bolt threads 271 Apply Loctitet 271 to the bolt threads 242 242 271 271 NOTE Heat the oil baffle bolts with a heat gun to remove Gasket 262 262 242 Apply Loctitet 262 to the bolt threads 271 ...

Page 55: ... 15 18 Nm 16 20 ft lbs 22 27 Nm 8 5 9 5 ft lbs 12 13 Nm Rocker Cover Breather Cover Reed Cylinder Head Head Gasket Cylinder Base Gasket Exhaust Manifold Exhaust Gasket Thermostat Cover Thermostat Temperature Switch Frost Plug Carburetor Apply Loctitet 242 to the bolt threads Apply Loctitet 271 to the bolt threads 242 271 271 271 271 271 271 16 20 ft lbs 22 27 Nm ...

Page 56: ...26 30 ft lbs 35 41 Nm 20 24 ft lbs 27 33 Nm Piston Assembly Crankshaft Gears Woodruff Key Balance Shaft Lifter Valve Valves Pushrods Valve Seals Valve Springs Rocker Arms Cylinder Head Camshaft Thrust Plate Camshaft Gears Apply Loctitet 242 to the bolt threads Apply Loctitet 271 to the bolt threads 242 271 271 242 242 ...

Page 57: ...Nm 8 5 9 5 ft lbs 12 13 Nm Oil Filter Water Oil Pump Gear Impeller Bearing Water Oil Shaft Oil Pump Housing Gerotor Oil Filter Nipple O Ring Water Pump Seal Water Pump Cover Gear Stator Housing Oil Plug Apply Loctitet 242 to the bolt threads Apply Loctitet 271 to the bolt threads 242 271 Oil Pressure Relief 242 8 5 9 5 ft lbs 12 13 Nm 271 Gasket ...

Page 58: ...s 6 7 Nm 8 5 9 5 ft lbs 12 13 Nm 8 5 9 5 ft lbs 12 13 Nm 7 9 ft lbs 10 12 Nm Stator Bolts Flywheel Stator Housing Sound Cover Outer Cover Starter Bendix Timing Plug Washers O rings Stator Wire Holddown Flywheel Nut Apply Loctitet 242 to the bolt threads Apply Loctitet 271 to the bolt threads 242 271 271 242 242 242 242 ...

Page 59: ...43 Universal Driver Handle PU 45483 Main Seal Installer PU 45658 Main Crankshaft Seal Saver PA 45401 Water Pump Seal Saver 2870975 Mity Vact Pressure Test Tool PU 45778 Oil System Priming Tool ACCESSIBLE COMPONENTS The following components can be serviced or removed with the engine installed in the frame G Flywheel G Alternator Stator G Starter Motor Starter Drive G Cylinder Head G Cylinder G Pist...

Page 60: ... 12 mm 20 22 27 30 Nm Oil Fill Tube Bolt 5 mm 4 5 5 5 6 7 Nm Oil Filter Pipe Fitting 20 mm 33 37 45 50 Nm Oil Pick Up 5 mm 4 5 5 5 6 7 Nm Oil Pressure Relief Plug 10 mm 20 24 27 33 Nm Oil Pressure Switch 1 4 18 8 5 9 5 12 13 Nm Oil Pump Housing Screw 6 mm 8 5 9 5 12 13 Nm Rocker Arm 8 mm 20 24 27 33 Nm Rocker Cover 6 mm 8 5 9 5 12 13 Nm Spark Plug 14 mm 16 20 22 27 Nm Starter Motor 6 mm 8 5 9 5 12...

Page 61: ... 10 11 12 13 14 15 1 2 4 5 6 3 PISTON IDENTIFICATION Four stroke engine rings have a rectangular profile See text onPage 3 27for ringinstallation Use theinformation below to identify pistons and rings NOTE The pistons have no directional identification marks New pistons are non directional Engine Model No Piston Length Standard Piston Identification EH680ALE 80 mm None EH590ALE 76 50 mm None ...

Page 62: ...H d Surface warpage limit 0 00394 0 1 mm y Head Standard height 3 478 88 35 mm Valve Seat Contacting width In Std 0 0472 0 00787 0 0039 1 20 0 20 0 10 mm Ex Std 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Seat Angle Std 44 75 r 0 25q Valve G id Inner diameter 0 2374 r 0 00059 6 030 r 0 015 mm Guide Protrusion above head 0 5610 r 0 00394 14 25 r 0 10 mm Valve Margin thick In Std 0 1394 r 0 0065 3 541 r...

Page 63: ...ston ring installed Top ring Piston Ring Piston ring installed gap Top ring Limit 0 01181 r 0 00039 0 30 r 0 01 mm g g Second Second ring Limit 0 01476 r 0 00492 0 375 r 0 125 mm Oil ring Oil ring Limit 0 00984 r 00393 0 25 r 0 10 mm Standard clearance Top ring Standard clearance i t i t i Top ring Limit 0 0019 r 0 00069 0 0475 r 0 0175 mm piston ring to ring groove Second groove Second ring Limit...

Page 64: ...d Surface warpage limit 0 00394 0 1 mm y Head Standard height 3 478 88 35 mm Valve Seat Contacting width In Std 0 0472 0 00787 0 0039 1 20 0 20 0 10 mm Ex Std 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Seat Angle Std 44 75 r 0 25q Valve G id Inner diameter 0 2374 r 0 00059 6 030 r 0 015 mm Guide Protrusion above head 0 5610 r 0 00394 14 25 r 0 10 mm Valve Margin thick In Std 0 1394 r 0 0065 3 541 r 0...

Page 65: ...Piston Piston ring installed Top ring Piston Ring Piston ring installed gap Top ring Limit 0 01083 r 0 00295 0 275 r 0 075 mm g g Second Second ring Limit 0 0177 r 0 00394 0 45 r 0 10 mm Oil ring Oil ring Limit 0 0177 r 00984 0 45 r 0 25 mm Standard clearance Top ring Standard clearance i t i t i Top ring Limit 0 0019 r 0 00069 0 0475 r 0 0175 mm piston ring to ring groove Second groove Second rin...

Page 66: ...ing systems and comes pre mixed ready to use Radiator Thermostat Cylinder Head Water Pump Cylinder FLOW COOLING SYSTEM WARNING Never remove radiator cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine and cooling system to cool before servicing 1 Remove front cover 2 Remove recovery bottle hose from coolant filler neck 3 Connect a Mity ...

Page 67: ...connect the coolant hoses Properly dispose of any antifreeze from the engine or hoses 13 Refer to PVT System Chapter 6 to remove outer clutch cover drive belt drive clutch driven clutch and inner cover D 14 When removing starter cables note and mark ground cable and positive cable mounting angle and locations Remove cables 15 Remove transmission linkage rod from gear selector and secure out of the...

Page 68: ...d observe coolant level in the radiator Allow air to purge and top off as necessary Reinstall radiator cap and bring engine to operating temperature After engine is cool check level in reservoir tank and add coolant if necessary NOTE Should the reservoir tank become empty it will be necessary to refill at the radiator and repeat the bleeding procedure Engine Break In Period The break in period for...

Page 69: ...der to heat up during honing G After honing has been completed inspect cylinder for thinning or peeling If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable Hone only enough to deglaze the outer layer of the cylinder bore EXAMPLE OF CROSS HATCH PATTERN IMPORTANT Clean the Cylinder After Honing It ...

Page 70: ...th the first path entering the camshaft bores onto the rear balance shaft journal and then draining back into the crankcase sump The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump T...

Page 71: ...hen workingwith compressed air to prevent personal injury 3 Check the ends of the push rods A for nicks grooves roughness or excessive wear 4 The push rods A can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness 5 If the push...

Page 72: ... head is still on the engine Keep all parts in order with respect to their location in the cylinder head WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly 1 Having already removed the valve cover rocker arms and pushrods align the cylinder to be worked on at top dead center Install the Valve Pressure Hose PU 45652 into the spark plug hole Hook the hose to...

Page 73: ...a Vernier caliper Compare to specifications Replace spring if measurement is out of specification Valve Spring Free Length Valve Spring Length Std 1 827I 46 40 mm Installed Height 1 47 37 34 mm 6 Remove valve guide seals IMPORTANT It is recommended to replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildu...

Page 74: ...f valve stem with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications Valve Stem Diameter Intake 0 2356 r 0 00039 5 985 r 0 01 mm Exhaust 0 2346 0 00039 5 96 0 01 mm Measure valve stem in several places Rotate the valve 90 degrees and mea sure for wear 6 Measure valve guide inside diameter at the top middle and end of the guide usi...

Page 75: ... with the valve seat cutters in the Cylinder Head Reconditioning Kit PN 2200634 Abrasive stone seat reconditioning equipment can also be used Keep all valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumference of the seat and the seat must be the pro...

Page 76: ...icates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be the proper width G If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too high on the valve face Use the 30 cutter to lower the valve seat G If too low use the 60 cutter to raise the seat When contact area is centered on...

Page 77: ...the valve is fully seated and repeat process for the other valve s 12 Thoroughly clean cylinder head and valves CYLINDER HEAD REASSEMBLY NOTE Assemble the valves one at a time to maintain proper order 1 Apply engine oil to valve guides and seats 2 Install new valve seals on valve guides 3 Coat valve stem with molybdenum disulfide grease or 0W 40 Synthetic oil 4 Install valve carefully with a rotat...

Page 78: ...ean solvent onto the intake port and check for leakage around each intake valve The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into exhaust port A VALVE TRAIN EXPLODED VIEW HEAD VALVES SPRINGS RETAINER LOCKS SPRING RETAINERS GUIDE SEALS ROCKER ARMS PUSH RODS HYDRAULIC LIFTERS 20 24 FT LBS 27 32 50 NM ...

Page 79: ...l cylinder head on cylinder 3 Install head bolts C Torque bolts to 60 64 ft lbs 81 87 Nm following torque pattern on Page 3 9 C Cylinder Head Bolt Torque 60 64 ft lbs 81 87 Nm 4 Lubricate push rods D and install into lifters D 5 Lubricate rockers E with engine oil E 6 Verify pushrods are engaged in lifters 7 Install rockers Be sure that tab of fulcrum F is seated in head stand off Torque bolts to ...

Page 80: ... 13 Nm REMINDER Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts and new Loctitet 10 Install rocker cover Apply Loctitet 271 PN 2871954 to the bolts Torque bolts to 8 5 9 5 ft lbs 12 13 Nm Rocker Cover Bolt Torque 8 5 9 5 ft lbs 12 13 Nm 11 Install thermostat J Apply Loctitet 271 PN 2871954 to the bol...

Page 81: ...uring engine reassembly Mark the Hydraulic Lifter 4 Check the lifters for wear or scores 5 Check the bottom end of lifter to make sure that it has a slight convex 6 If the bottom surface has worn flat it may be used with the original camshaft only Inspect Hydraulic Lifter NOTE Lifters that are scored worn or if the bottom is not smooth should be replaced with new lifters and cam as an assembly If ...

Page 82: ...second ring 5 Remove the oil control ring The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section The top rail has a locating tab on the end which fits into a notch B in the upper oil ring land of the piston To Remove a Remove the top rail first followed by the bottom rail b Remove the expander Oil Ring Compression Rings B CYLINDER INSPE...

Page 83: ...rom Top of Cylinder 1 2s Up From Bottom X X Y Y X Y 5 Record measurements If cylinder is tapered or out of round beyond 002 the cylinder must be replaced Cylinder Taper Limit 002I 05mm Max Cylinder Out of Round Limit 002I 05mm Max Standard Bore Size Both Cylinders Sportsman 700 3 1496I 80 mm Sportsman 600 3 0018 76 50 mm PISTON TO CYLINDER CLEARANCE Measure piston outside diameter at a point 5 mm ...

Page 84: ...19 0 007 r 0 005 mm 700 0 00059 r 0 0002 0 015 r 0 005 mm 2 Measure piston pin O D Replace piston and or piston pin if out of tolerance Piston Pin Measurement Locations Piston Pin O D 0 7874 7872 20 19 995 mm 3 Measure connecting rod small end ID Connecting Rod Small End I D 789 78841 20 030 20 015 mm 4 Measure piston ring to groove clearance by placing the ring in the ring land and measuring with...

Page 85: ... bottom of the cylinder REMINDER 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 smaller than the specified limit file ring ends until gap is within specified range NOTE Always check piston ring installed gap after re boring a cy...

Page 86: ...tarter drive B Replace starter drive if gear teeth are cracked worn or broken 7 Inspect the bendix bushing C in the mag cover for wear Replace as needed C FLYWHEEL STATOR REMOVAL INSPECTION 1 Remove stator housing bolts and remove housing 2 Remove flywheel nut and washer 3 Install Flywheel Puller PN 2871043 and remove flywheel A CAUTION Do not thread the puller bolts into the flywheel more than 1 ...

Page 87: ...y LocTitet242 PN 2871949 onto the bolts Inspect the bolts if new bolts are needed replace them with new bolts The new bolts contain patch lock so Loctitet is not needed on the new bolts Torque bolts to 9 10 ft lbs 12 14 Nm 3 Install the starter bendix if removed 4 Install woodruff key Install the flywheel Install the flywheel washer and nut Apply Loctitet 242 PN 2871949 onto the threads Torque the...

Page 88: ...and water pump impeller E Remove part of the water pump seal behind the impeller E C D 3 Remove flywheel nut and washer 4 Install Flywheel Puller PN 2871043 and remove flywheel F CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 2871043 F 5 Remove the starter bendix G wire holddown plate H and the woodruff key I from the crankshaft The stator doe...

Page 89: ...are to be replaced camshaft gear K water oil pump gear L crankshaft gear M or counterbalance gear N Cam Gear Removal 9 Use the Cam Gear Tooth Alignment Tool PU 45497 2 O to align the cam split gear assembly With the split gear aligned remove the bolt and cam gear assembly PU 45497 2 O NOTE Install the Cam Gear Tooth Alignment Tool PU 45497 2 into the assembly hole counter clockwise from the timing...

Page 90: ...OUT 12 Remove all three springs using one of the tapered pins from the Tapered Pins PU 45497 1 PU 45497 1 PU 45497 1 13 With a white marking pen accent the timing mark on the gear that contains the springs Accent the Timing Marks 14 Inspect the gear teeth and the three tabs on the gears for wear It is recommended to replace the springs whenever the gear is taken apart Inspect Teeth Tabs Replace Th...

Page 91: ...stallation Tool Kit PU 45497 Tapered Pins PU 45497 1 Cam Gear Tooth Align Tool PU 45497 2 18 Line up the two gears using the timing marks and the three gear tabs that were referenced earlier Push the gears back together using both hands and hold securely Align Timing Marks 19 Once the gears are pressed together firmly hold the gears together with one hand Carefully remove the Tapered Pins PU 45497...

Page 92: ...ntire valve train is assembled If the rocker arms are removed the cam shaft can be turned by hand 22 Remove the bolt and nut from the balance shaft gear Try to remove the balance shaft gear If the gear does not come off manually use the Flywheel Puller PN 2871043 to remove the balance shaft gear 2871043 23 Inspect the crankshaft gear Q for broken orworn teeth If the crankshaft gear does not need t...

Page 93: ...tors are installed and mesh with the same edges as previously installed Mark Rotors NOTE If replacing the old rotors new replacement rotors will fit into the old oil water pump housing 28 Remove the oil pressure relief The oil pressure relief consists of a bolt washer spring and valve dowel Inspect the the valve dowel for signs of possible obstructions Use compressed air to blow out any debris 29 ...

Page 94: ...uring this procedure Heat resistant gloves clothing and eyewear are required 30 Heat oil water pump drive housing T Remove from shaft using a soft hammer Heat Housing T 31 Remove the gear shaft from the water oil pump housing 32 Press gear from shaft Press out gear 33 Press bearing from shaft Replace the old bearing with a new bearing during assembly Bearing WATER OIL PUMP REASSEMBLY 34 Press shaf...

Page 95: ... Heat resistant gloves clothing and eyewear are required 37 Remove thrust plate U U 38 Remove PTO end engine mount Remove crankcase bolts Tap on the reinforced areas on the cases using soft hammer Carefully separate the two crankcase halves Separate the crankcase halves NOTE Only remove the oil baffle if the baffle is damaged When removing the oil baffle bolts use a heat gun to heat the bolts and ...

Page 96: ...ngs for abnormal wear It is recommended to replace the bearings anytime the engine is disassembled CAMSHAFT INSPECTION 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage Lobe height 3 Measure height of each cam lobe using a micrometer Compare to specifications Cam Lobe Height Intake Exhaust Std 0 2170 0 00236 5 5118 0 060 mm 4 Measure camshaft journal outs...

Page 97: ...E LOWER REASSEMBLY WARNING After any reassembly or rebuild the engine must be primed using the Oil Priming Adapter PU 45778 and a 3 4 full oil filter before initial start up Follow Steps 44 45 in this section to properly prime the engine and to help aid proper engine break in NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper s...

Page 98: ...ankshaft assembly and apply engine oil to crank pins and rods D Apply Starter Drive Grease PN 2871460 to the main journals and bearings D 6 Apply Crankcase Sealant PN 2871557 to PTO gearcase halve E NOTE Do not apply sealant to cam relief hole E 7 Assemble the crankcase halves Apply LocTitet 242 PN 2871949 Torque bolts to 20 24 ft lbs 27 33 Nm following torque pattern on Page 3 2 Crankcase Bolt To...

Page 99: ...e cylinder gasket to help hold it in place during cylinder assembly DO NOT USE SILICONE 12 Install piston assemblies into cylinder aligning the piston pin holes to ensure proper alignment of the pistons to the connecting rods upon assembly Partially install the piston pins into the pistons Cylinder Installation NOTE To help align the pistons slide a rod that is close to the same diameter as the wr...

Page 100: ...t lbs 6 7 Nm NOTE New bolts have patch lock on the threads and do not require Loctitet G 16 Assemble rotors as marked when disassembled Use a cleaner to remove the marks previously made on the rotors Line Up Marks 17 Apply starter grease lubriplate or oil to the rotors on the oil pump shaft NOTE The application of oil or lubriplate aids in priming the oil pump during initial engine start up Lubric...

Page 101: ...ng a replacement gear all of the gears will be shipped automatically to ensure all of the gears are replaced This helps to ensure proper gear mesh and helps to prevent abnormal gear wear All Gears Replaced As A Set 19 Install oil pump housing bolts H The new bolts contain patch lock so Loctitet is not needed on the new bolts Torque bolts to 8 5 9 5 ft lbs 11 5 13 Nm NOTE Occasionally spin the oil ...

Page 102: ... balance shaft gear J with new key aligning timing marks with crankshaft gear I Apply LocTitet242 PN 2871949 to the bolt threads Install washer and bolt Use the Gear Holder PU 45648 Torque to 26 30 ft lbs 35 41 Nm I PU 45648 J Gear Holder PU 45648 25 Use the Cam Gear Alignment Tool PU 45497 2 to align the teeth of the cam gear M Install the cam gear M with the Cam Gear Alignment Tool still in plac...

Page 103: ...installation Thoroughly clean parts tools and hands before installation 27 Before installing the gear stator housing replace the seals in the cover Install a new water pump seal N into the gear stator housing O Use the Water Pump Mechanical Seal Installer PA 44995 to properly install the seal to the correct depth in the cover PA 44995 O N NOTE To remove the water pump seal the gear stator housing ...

Page 104: ...the paper seal lip 30 Carefully install the tapered end of the Crankshaft Seal Protection Tool PA 45658 through the paper side of the crankshaft seal Back to Front Leave the seal protector installed in the crankshaft seal Check the crankshaft seal lips to verify they have not been rolled or damaged PA 45658 31 Before installing the gear stator housing cover install the Water Pump Seal Saver PA 454...

Page 105: ...he bolts Torque bolts to 8 5 9 5 ft lbs 12 13 Nm in a criss cross pattern Remove seal protectors from the shaft ends once secure PA 45401 PA 45658 O NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts and new Loctitet Gear Stator Housing Cover Bolt Torque 8 5 9 5 ft lbs 12 13 Nm 36 Install shaft sea...

Page 106: ...ly S and bolts Apply Loctitet 242 PN 2871949 to the bolts Torque bolts to 9 10 ft lbs 12 14 Nm 41 Install the the wire hold down bracket T Install two new wire hold down bolts New bolts contain patch lock so Loctitet is not needed on the new bolts Torque bolts to 9 10 ft lbs 12 14 Nm Coat the stator wire grommet U with Nyogelt Grease PN 2871329 NOTE Be sure the stator wires are routed properly und...

Page 107: ...e filter onto the engine Fill 3 4 full with 0W 40 oil 45 Remove primer plug from the engine Install the Oil System Priming Adapter PU 45778 into the oil plug hole Push 3 5 oz approx of Polaris 0W 40 into the adapter until resistance is felt Remove the adapter Apply pipe dope or Teflon tape to the plug threads Install the plug and torque to 7 9 ft lbs 9 50 12 Nm PU 45778 Oil System Priming Adapter ...

Page 108: ...G Fuel will not pass through fuel valve G Fuel pump inoperative restricted G Tank vent plugged or pinched G Carb starter circuit plugged G Engine flooded G Low compression high cylinder leakage G No spark Spark plug fouled ignition component failure Engine Does Not Turn Over G Dead battery G Starter motor does not turn G Engine seized rusted or mechanical failure Engine Runs But Will Not Idle G Re...

Page 109: ...lug cap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key G Poor connections in ignition system G Valve sticking G Air leaks in intake G Lean condition COOLING SYSTEM TROUBLESHOOTING Overheating G Low coolant level G Air in cooling system G Wrong type mix of coolant G Faulty pressure cap or system leaks G Restricted system mud...

Page 110: ...eck will aid in purging the system of air Pump the hose using your hand several times as shown in the diagram Elevating the rear of the ATV with a floor jack rear tires 4 6 off the ground also aids the purging of air from the system 3 Always add coolant to the radiator first filling to the top of the neck to replace air that has been purged from the system Fill the reservoir only after you have co...

Page 111: ...4 Carburetor Jetting 4 4 Main Jet Pilot Jet Part Numbers 4 4 CV Carburetor System Function 4 Cycle 4 5 CV Carburetor Vent System 4 Cycle 4 5 CV Carburetor Operation 4 5 4 7 Disassembly Notes CV Carburetor 4 7 4 8 Cleaning CV Carburetor 4 8 Inspection CV Carburetor 4 9 Assembly CV Carburetor 4 9 Float Adjustment CV Carburetor 4 10 Needle Seat Leakage Test 4 10 Fuel Level 4 11 Fuel Pump Service 4 11...

Page 112: ...ng 18 Packing 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 S...

Page 113: ...ASSEMBLY Forward Foam Seal 3 Way Fuel Valve Fuel Knob Main Fuel Outlet Tank Fuel Cap Tank Vent Fuel Tank Foil Fuel Tank 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 114: ...ltitude of 0 6000 ft 0 1800 meters and ambient temperatures between 40 and 80q F 5q to 26q 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 CARBURETOR JE...

Page 115: ...ies fuel at 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 carb...

Page 116: ...ntations of 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 b...

Page 117: ... Pipe 1 4 2 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 clearan...

Page 118: ...ould you get 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 no...

Page 119: ...a Jet Needle 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 pl...

Page 120: ...n the inlet needle valve pin without compressing the spring Float Height Std BST 34 13 14 mm 51 55 inches 2 Measure the height from the float bowl mating surface to the top of step in float as shown Both sides of float should be parallel to each other The measurement should be made at the mid point on the top of the float using Float Adjustment Tool PN 2872314 or a vernier caliper When measuring t...

Page 121: ...p 1 Turn fuel off 2 Disconnect impulse line from pump 3 Connect Mity Vact PN 2870975 to the impulse line fitting on the pump 4 Apply 5 inches Hg vacuum to the pump fitting The diaphragm should hold vacuum indefinitely If fuel is present in the impulse line or vacuum chamber of the pump the diaphragm is ruptured The pump diaphragms must be replaced Fuel Filter Fuel Pump Impulse line FUEL PUMP DISAS...

Page 122: ...rty plugged 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 ...

Page 123: ... 4 Steering A Arm Exploded View 5 5 Rear Suspension Exploded View 5 6 Front Strut Assembly Exploded View 5 7 Special Tools Torque Specifications 5 8 Cover Panel Removal 5 8 Side Panel Removal 5 9 A Arm Replacement 5 9 5 10 Steering Post Assembly 5 10 Front Strut Cartridge Replacement 5 11 Front Strut Ball Joint Replacement 5 11 5 12 Decal Replacement 5 12 ...

Page 124: ...ce when body parts are assembled Rear Cab Assembly Front Cab 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 Splash Guard Deflector Shield Frame Frame Footrest Seat Latch Frame Brace Clutch Guard ...

Page 125: ...ION BODY STEERING SUSPENSION 5 3 Rear Rack Extender Rear Rack Reflector Rear Support Rack Frame Front Rack Extender Front Rack Front Support Rack Bumper Panel Side Shield Radiator Cover Grill Brush Guard Frame Lower Bumper ...

Page 126: ... headlight with adjuster G Remove two screws securing bottom half of pod E Assembly G Install bottom of pod onto handlebar and secure to brackets G Install key switch choke cable and headlight G Connect 12V power outlet where applicable G Connect headlight G Connect speedometer connectors to speedometer G Install top of pod onto bottom half making sure interlocking tabs mate properly G Install two...

Page 127: ...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 Loctitet 242 to the bolt threads 242 242 BODY STEERING SUSPENSION BODY STEE...

Page 128: ... lbs 24 Nm 30 ft lbs 41 Nm 17 ft lbs 24 Nm 35 ft lbs 48 Nm Upper Control Arm Lower Control Arm 35 ft lbs 48 Nm Stabilizer Support Wheel Bearing Carrier A Arm Bushing Skid Plate Strap Rear Shock Lower Control Bushing Stabilizer Bar Arm Orientate Bushings Correctly Rear Front Bushing Orientation Forward 1 1 ...

Page 129: ...location Check lubrication guide for recommended service intervals 15 ft lbs 21 Nm Nut 15 ft lbs 21 Nm 18 ft lbs 25 Nm Washer Upper Pivot Ball Lower Pivot Ball Spacer Rubber Spring Retainer Spring Bolt Spacer Nut Washer Clamp Strut Strut Bumper Hubstrut Bearing Retaining Ring Lubrication Fitting Brake Caliper ...

Page 130: ...efer to exploded views for identification and location of components COVER PANEL REMOVAL To Remove Seat Pull release lever at the rear of the seat Lift and pull seat rearward disengaging seat from tabs at the rear of the fuel tank To Remove Side panels See Page 5 9 Remove Seat Disengage tabs at front and rear and pull away To Remove Headlight pod See Page 5 4 To Remove Front Cover Remove Front rac...

Page 131: ...wo tabs into the rear cab To reinstall align panel tabs with slots Push upward and forward until tabs lock Step 3 A ARM REPLACEMENT 1 Elevate and safely support vehicle with weight removed from front wheel s Remove wheels 2 Remove cotter pin from ball joint stud at wheel end of A arm and loosen nut until it is flush with end of stud 3 Using a soft face hammer tap nut to loosenA arm from bolt Remov...

Page 132: ...ation completion test vehicle at low speeds before putting into regular service Vehicle Frame Grease Fitting Nut Cotter Pin Ball Joint Stud CV Joint Shield A Arm Tube A Arm Shaft Bolt 30 ft lbs 41 Nm Washer 25 ft lbs 35 Nm 8 ft lbs 11 Nm Bolt 30 ft lbs 41 Nm Long Bushing Bushing Apply Loctitet 242 to the bolt threads 242 242 STEERING POST ASSEMBLY 1 Hand tighten 2 Align cotter pin hole 3 Install c...

Page 133: ...21 Nm BALL JOINT REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5 7 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 4 Remove cotter pin A from ball joint castle nut 5 Remove castle nut B and separate...

Page 134: ...y from gasoline or other flammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue The side panels front and rear fender cabs are plastic polyethylene material Therefore they must be flame treated prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress m...

Page 135: ...ly 6 7 PVT Assembly Inspection 6 8 Drive Clutch Spring Specifications 6 9 Shift Weights Inspection 6 10 6 11 Drive Clutch Disassembly Inspection 6 11 6 13 Drive Clutch Reassembly 6 13 6 14 Drive Belt Removal Inspection 6 14 6 15 Drive Belt Installation 6 16 Clutch Alignment Offset 6 16 6 17 Drive One way Clutch Inspection 6 17 6 18 Driven One way Clutch Inspection 6 18 6 20 Drive Clutch Bushing Se...

Page 136: ...ve Clutch Mark with permanent marker before disassembly One way clutch PVT SEALING AND DUCTING COMPONENTS Clutch Cover Clutch Inlet Duct Clamps Clutch Cover Seal Seal Retainer Bracket Inner Cover Seal Transmission Cover Seal Inner Clutch Cover Boot Duct ...

Page 137: ...e Way 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 138: ... 2 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 ran...

Page 139: ... Offset 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...

Page 140: ...ures 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...

Page 141: ... 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 offset ...

Page 142: ...nt A 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 was...

Page 143: ...ase 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 ...

Page 144: ...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 PN 5631214 20 54 54 gr 20 56 PN 563121...

Page 145: ...nly 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 CL...

Page 146: ...for wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See Page 6 9 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 287034...

Page 147: ...ushing 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 t...

Page 148: ...erting 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 cover bolts eve...

Page 149: ...e cords missing cogs cracks abrasions thin spots or excessive wear Replace if necessary 6 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt continuously in one spot 7 Measure belt length with a tape measure around the outer circumference of the belt Be...

Page 150: ...7 6 8 4 Remove PVT inner cover 5 Loosen all engine mounts Move front of engine to the right or left slightly until alignment is correct 6 Tighten engine mounts and verify alignment is correct 7 Measure belt deflection and measure offset both above and below shaft centerlines Adjust if necessary Center line Measure offset above and below centerline NOTE On some models minor adjustments can be made ...

Page 151: ...y 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 inspect the...

Page 152: ...ng 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 DRIVEN CLUTCH DISASSEMBLY INSPECTION CAUTION The driven clutch must be disassembled from the helix end to lessen the chance of damage ...

Page 153: ...lace if worn 6 Inspect surface of rollers for flat spots and wear Rollers must rotate freely on pins without excessive clearance Check the roller pin and roller bore for wear and replace if necessary Rollers ROLLER PIN DISASSEMBLY New roller retaining bolts have a dry locking agent applied to the threads Before attempting to remove the roller pins heat the threaded area lightly with a propane torc...

Page 154: ...132501 D 1 EBS Main Adapter 5132029 E 1 EBS Bushing 5132028 Removal Tool 1 Instructions 9915111 Also required Clutch Bushing Replacement Tool Kit PN 2871226 ATV Clutch Kit or PN 2871025 For all clutches Piston Pin Puller PN 2870386 REMOVAL AND INSTALLATION INSTRUCTIONS NOTE Bushings are installed at the factory using Loctitet 609 In order to remove bushings it will be necessary to apply heat evenl...

Page 155: ...terclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 8 Remove nut from puller rod and set aside 9 Remove sheave from puller 10 Remove installation tool EBS Drive Clutch Cover Bushing Removal 1 Install main adapter Item 8 on puller Main Adapter 8 Removal Tool 3 Piston Pin Puller Nut C Adapter Reducer 9 EBS Drive Clutch Cover Bushing Removal 2 Install adapter...

Page 156: ... Slide adapter Item 10 onto puller Nut C Bushing EBS Driven Clutch Bushing Installation Puller Adapter 10 Puller Tool A B Side B toward sheave 2 Apply Loctitet 609 evenly to bushing bore inside moveable sheave 3 Install sheave onto puller belt surface up 4 Place new bushing on side B of installation tool Item A B and slide both over puller rod 5 Install nut C onto puller rod and hand tighten again...

Page 157: ...ller 2 Install adapter Item 9 onto puller Nut C Bushing Tool 2 Bushing EBS Driven Clutch OuterBushing Installation Adapter 9 Puller Adapter 10 3 Apply Loctitet 609 evenly to bushing bore inside moveable sheave 4 Install sheave face down on puller 5 Install new bushing on installation tool Item 2 and install assembly into sheave 6 Install left hand thread nut C onto puller rod and hand tighten agai...

Page 158: ...emble 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 belt Harsh drive clutch engage ment Drive belt worn too ...

Page 159: ...utch 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 wor...

Page 160: ...CLUTCH CLUTCH 6 26 NOTES ...

Page 161: ...oval 7 8 7 9 Front Gearcase Operation 7 9 7 10 Front Gearcase Disassembly Inspection 7 10 7 12 Front Gearcase Assembly Inspection 7 12 7 14 Front Gearcase Diagnosis 7 14 7 15 Front Gearcase Installation 7 15 Front Gearcase Exploded View 7 16 Rear Hub Removal 7 17 7 18 Rear Hub Installation 7 18 7 19 Rear Hub Disassembly 7 19 7 20 Rear Hub Assembly 7 20 Rear Driveshaft Removal 7 20 Driveshaft and C...

Page 162: ...nt and 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 FINAL DRIVE 7 2 AWD FRONT DRIVE AXLE EXPLODED VIEW ...

Page 163: ...ub and check for movement 3 If movement is detected inspect hub hub nut torque and bearing condition and correct as necessary FRONT DRIVE AXLE REMOVAL 1 Set the ATV in park Remove hub dust cap 2 Remove cotter pin 3 Loosen the hub retaining nut 4 Loosen but do not remove the wheel nuts 5 Safely lift and support the front of the ATV CAUTION Serious injury could occur if machine tips or falls 6 Remov...

Page 164: ...llowing these instructions is very important to ensure proper shaft function and a normal service life G 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 G Over angling of joints beyond their capacity could result in boot or joint damage G Make sure surface ground areas and splines of ...

Page 165: ...a damaged boot the CV joint grease may be contaminated Inspect the grease carefully for contamination and clean the joint thoroughly if necessary Front drive axle CV boot replacement requires 30g of grease If CV joint is cleaned an additional 30g of grease is required Refer to information following 8 Before installing the new boot remove all grease from the boot area and shaft NOTE It is very impo...

Page 166: ...e 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 FRONT HUB ASSEMBLY 1 Support bottom of hubstrut housing 2...

Page 167: ...inner and outer yoke for correct re positioning during installation 2 Support 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 REASSEMBLY 1 Install new bearing caps in yoke by hand Carefully install U...

Page 168: ...llation is complete Yokes must pivot freely in all directions without binding If the joint is stiff or binding tap the yoke lightly to center the joint until it pivots freely in all directions FRONT GEARCASE REMOVAL 1 Stop engine place machine in Park and set parking brake 2 Loosen right front wheel nuts slightly 3 Elevate and support machine under footrest frame area CAUTION Serious injury may re...

Page 169: ...ove vent line Remove the front gearcase from right side of frame Frame Front Gearcase FRONT GEARCASE OPERATION CENTRALIZED HILLIARD Normal Operation With the AWD switch off the vehicle is only driving the rear wheels 2 wheel drive When the AWD switch is activated it engages the Hilliard and locks both front wheels and we then have True All Wheel Drive Coil Cover Output Hub Armature Plate Engagemen...

Page 170: ...rive Roller Cage and Bearing s Rotate Inward and Grip the Output Hub for AWD Engagement Output Hub Rollers Roller Cage Roller Cam FRONT GEARCASE DISASSEMBLY INSPECTION 1 Drain and properly dispose of used oil Remove any metal particles from the drain plug magnet 2 Remove bolts and output shaft cover Front Gearcase Coil Resistance 22 8 25 2 Ohms Gearcase Coil Resistance NOTE To test the gearcase co...

Page 171: ... scratches 8 Inspect roll cage B sliding surface This surface must be clean and free of nicks burrs or scratches Remove and inspect the H springs B H spring 9 Remove the ring gear C the output hub D the shim E and the armature plate F from the output cover D C F E Coils 10 Inspect the armature plate F for a consistent wear pattern Uneven wear of the armature plate F indicates a warped plate which ...

Page 172: ...nion cover until the seal is flush with the sealing surface 3 Inspect bearings on output and pinion shafts To replace press new bearing on to shaft NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detecta...

Page 173: ...all the shim onto the ring gear 9 Install the armature plate onto the ring gear NOTE Be sure armature plate tabs are placed into the slots on roll cage 10 Apply grease to the thrust bearing Insert the thrust bearing onto the output hub Insert the output hub dowel and thrust bearing into the ring gear 11 Install output cover with new o ring and torque bolts to 14 ft lbs 19 Nm ...

Page 174: ...If only one band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 4 A band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation See Illustration 1 Armature Plate Check for wear bands Possible Wear Ring on Armature Plate OK Condition Bad Condition Wear from Coil On Armature Plate ILL 1 4 Check to make...

Page 175: ...freely within the roll cage sliding surfaces Rollers FRONT HOUSING INSTALLATION 1 To install gearcase reverse removal procedure Use new spring pin in front prop shaft New spring Pin 2 Add the proper lubricant to the front gearcase Check drain plug for proper torque Refer to Page 2 10 in the maintenance chapter for fill capacities Premium Front Housing Fluid PN 2871654 Front Housing Capacity 5 0 fl...

Page 176: ...Hub Race Output Male 27 1 Gearcase LH 8 1 Pin Dowel 28 2 Seal Oil 9 1 Bearing Roller Ball 29 1 Plug Oil Fill 10 1 Clutch Housing Ring Gear 30 4 Washer Spring Lock 11 1 Spring 31 4 Screw 12 14 Kit Roll 32 1 Plug Oil Drain 13 2 Ring Retaining 33 1 Washer 14 1 Bushing 34 1 Bearing Needle Roller Thrust 15 1 Hub Race Output Female 35 1 Roll Cage Aluminum 16 1 Bushing 36 1 Plate Armature 17 AR Line Fuel...

Page 177: ...he hub retaining nut 4 Loosen the wheel nuts 5 Safely support the rear of the ATV CAUTION Secure the machine Serious injury could occur if machine tips or falls 6 Remove wheel nuts and wheel 7 Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire 8 Remove hub nut domed washer and flat washer 9 Remove hub ...

Page 178: ...rease and slide lower control arm bushings into place securing corner housing Install upper and lower bolts Lower Control Arm Bolt Torque 40 ft lbs 54 Nm Upper Control Arm Bolt Torque 35 ft lbs 48 Nm 3 Install and torque both lower control arm bolts 4 Lift bearing carrier until top aligns with upper control arm Install and torque upper control arm bolt and torque to specification Rear Hub Nut Torq...

Page 179: ...ace with a drift punch in the reliefs as shown NOTE Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 3 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or ...

Page 180: ...ION Use an arbor press only on the outer race as bearing damage may occur 4 Install snap ring into groove REAR DRIVE SHAFT REMOVAL 1 Remove rear hub and bearing carrier See Pages 7 17 7 18 2 Tip hub outward and remove shaft from hub 3 Pull sharply outward to remove shaft from transmission Install a new lock ring upon assembly Pull outward sharply to re move from transmission Lock ring ...

Page 181: ...er suspension components G Never use a hammer or sharp tools to remove or to install boot clamps G Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV joints and CV joint boots REAR DRIVE SHAFT INSTALLATION 1 Slide shaft assembly into bearing carrier hub...

Page 182: ...from recess in CV joint 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 ta...

Page 183: ...cates 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 Cleaning Replacement NOTE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if compo...

Page 184: ...f the ATV and safely support the ATV with jackstands 3 Remove the two rear tires 4 Remove the rear prop shaft from the rear gearcase 5 Remove the rear drive shafts Refer to the Rear Drive Shaft Removal section 6 Remove the upper shock mounting bolt 7 Remove the four mounting bolts and washers A on the underside of the rear gearcase 8 Remove the two mounting bolts and washers B from the front of th...

Page 185: ...shim thrust button and thrust button shim from the gearcase Thrust Button Shims 4 Remove rear bevel gear from the gearcase housing cover 5 Inspect the ring gear for abnormal wear broken or chipped teeth Spin the bearing to check the ball bearings for smoothness Replace the bearing if needed 6 Remove the input shaft cover and the pinion shaft from the gearcase housing See next page ...

Page 186: ... check the ball bearings for smoothness Replace the bearing if needed REAR GEARCASE REASSEMBLY 1 Inspect the pinion shaft bushing for wear 2 Replace all O rings seals and worn components 3 Install the pinion shaft into the gearcase housing Install the pinion shaft cover and torque the cover bolts to 25 ft lbs 34 Nm ...

Page 187: ...the gearcase cover 5 Apply Crankcase Sealant PN 2871557 to surface of case and install cover bolts Install the gearcase cover onto the gearcase housing Torque the cover bolts to 25 ft lbs in a criss cross pattern Gearcase Cover Bolt Torque 25 ft lbs 34 Nm 6 Install the drain plugs Replace the drain plug washers to ensure proper sealing after filling ...

Page 188: ...haft 1 1 Cover Output LH 12 1 Ball Bearing 2 8 Screw 13 1 O ring 3 1 Tube Vent 14 1 Cover Input 4 2 Washer 15 1 Seall 5 2 Plug 16 1 Rear Gearcase Housing 6 2 Bearing Roller Ball 17 2 Ball Bearing 7 AR Shim 18 1 31T Gear 8 1 Thrust Button 19 AR Shim 9 2 Knock Pipe 10 1 Bushing 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2 5 4 6 16 17 18 17 19 ...

Page 189: ...SMISSION SERVICE Transmission Exploded View 8 2 8 3 Torque Specifications Lubrication 8 4 Gear Shift Selector Removal 8 4 Transmission Removal 8 4 8 5 Transmission Installation 8 5 Transmission Disassembly 8 5 8 11 Transmission Reassembly 8 11 8 15 ...

Page 190: ...VIEW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 17 20 3 21 22 23 21 22 13 36 35 34 31 25 26 27 28 29 33 31 32 31 30 29 28 25 13 26 27 13 37 38 39 40 41 42 1716 43 44 45 46 47 48 49 50 51 8 52 53 16 54 55 56 57 58 17 59 60 61 62 63 64 65 66 67 68 69 ...

Page 191: ... 13 4 Bearing 48 AR Shim 14 1 Silent Chain 49 AR Shim 15 1 Input Shaft 50 1 Front Output Cover 16 4 Bearing 51 17 Screw 17 4 Knock Pipe 52 1 Plug 18 1 LH Cover 53 1 Washer 19 1 Seal 54 1 Front Output Shaft 20 1 Shift Drum 55 1 Silent Chain 21 2 Shift Fork 56 1 22 22T Sprocket 22 2 Dowel Pin 57 1 Bushing 23 1 Shift Shaft Rail 58 1 Park Lockout 24 1 Park Plate 59 1 Main Gearcase 25 1 Engagement Dog ...

Page 192: ...ctor out of mounting bracket and away from frame TRANSMISSION REMOVAL 1 Remove seat rear rack rear cab air box and exhaust system and right footwell if required for access Front Transmission 2 Disconnect transmission vent line 3 Drain transmission lubricant 4 Disconnect shift linkage rod end from transmission bellcrank Linkage Rod Transmission Switch 5 Disconnect gear position switch harness 6 Rem...

Page 193: ...rom right side of vehicle 2 Align rear output shaft to rear propshaft yoke and roll pin hole 3 Slide rear output shaft into propshaft yoke 4 Position transmission in frame 5 Install front propshaft and roll pin 6 Loosely install left side and rear mounting brackets 7 Loosely install lower right bracket bolt 8 Loosely install front mounting bolts 9 Tighten mounting fasteners in order A F as shown N...

Page 194: ...r with a white pen Remove the detent gear from the case NOTE It may be helpful to place a mark just above the keyed spline 6 Mark the shift lockout disc this will indicate which sideof the disc faces outward during assembly Remove the shift lockout disc NOTE It may be helpful to place a mark just above the keyed spline 7 Remove the shift shaft and detent lever 8 Note the timing marks on the shift ...

Page 195: ... Then rotate the shift rail forks and shift drum so the the forks pins disengage fro the drum 11 Remove the shift drum NOTE You may have to tap the shift drum from the backside of the case to aid in removal 12 Remove the upper gear cluster and shift forks You may need to move the assembly back and forth to aid in removal 13 Set the upper gear cluster on a flat surface and inspect the components 14...

Page 196: ...reverse shaft using a puller 16 Remove the park lock engagement dog Remove the wave spring and reverse engagement dog Engagement Dogs 17 Remove the bearing from the input shaft with a puller 18 Remove the snap ring and washer from the reverse shaft 19 Remove low gear 33T and the needle bearing ...

Page 197: ...rest of the bearings from the shafts 22 Use a press to remove the gear from the shaft 23 Make note of the direction of the gear and hub location 24 Remove the gear split bearing and washer from the reverse shaft 25 Slide off the shift dogs and wave springs 26 Remove the snap ring washer gear and split bearing ...

Page 198: ... Remove the front housing cover screws 30 Remove the front housing cover shim thrust button and thrust button shim 31 Remove the shafts as an assembly 32 Remove the silent chain from the assembly for shaft inspection Note Location of Hubs 33 Clean all components in a parts washer and inspect for wear 34 Inspect engagement dogs of gears and replace if edgesare rounded ...

Page 199: ...ces are clean and dry and shafts are fully seated in the transmission case Apply Crankcase Sealant PN 2871557 to the mating surfaces Crankcase Sealant PN 2871557 4 Reinstall the thrust button shim thrust button and other shims into the cover Reinstall cover and torque bolts in a criss cross pattern in 3 steps to 27 34 ft lbs 36 50 46 Nm NOTE Make sure that the case locating pins knock pipes are in...

Page 200: ...over the shaft to avoid stressing the snap ring If the snap ring is over stressed it could come off the shaft and cause internal damage to the transmission 10 Slide the reverse shaft assembly through the silent chain 11 Install a new needle bearing the low gear the thrustwasher and the snap ring Use of a new snap ring is recommended 12 Install the engagement dogs wave springs and bearing 13 Instal...

Page 201: ...shaft assembly and gear cluster as a unit into their respective bearing case recesses Tap with a soft face hammer to seat shaft assemblies 16 Position the shift forks up and so the the pins point toward the 9 o clock position before installing the shift drum assembly 17 Replace and grease the O rings on the shift drum before installation 18 Install the shift drum into the case NOTE Make sure shift...

Page 202: ...lation Install new input shaft seal 23 Install drain plug with a new sealing washer Torque drain plug to 14 18 ft lbs 19 24 Nm Drain Plug Torque 14 18 ft lbs 19 24 Nm 24 Place a small amount of grease PN 2871551 into the pocket before installing the sector gear Install the shift gear 16T on the shift drum shaft Install the sector gear in the bushing pocket onthe left side Aligning the timing marks...

Page 203: ... bellcrank onto the shift shaft Note the keyed spline on the bellcrank and shaft Install the washer and nut Torque the bellcrank nut to 12 18 ft lbs 16 24 Nm Bellcrank Nut Torque 12 18 ft lbs 16 24 Nm 31 Install the shift switch Install the retaining clip Hook up the switch harness and reconnect the lockout plunger spring NOTE Rotate the bellcrank to line the flat side of the switch up to the flat...

Page 204: ...TRANSMISSION TRANSMISSION 8 16 NOTES ...

Page 205: ...sembly 9 8 9 9 Brake Burnishing 9 9 Front Disc Inspection 9 9 9 10 Front Disc Removal Replacement 9 10 Front Caliper Removal 9 10 Front Caliper Disassembly 9 11 9 12 Front Caliper Inspection 9 12 Front Caliper Reassembly 9 12 9 13 Front Caliper Installation 9 13 Front Caliper Exploded View 9 14 Rear Pad Removal 9 15 9 16 Rear Pad Installation 9 16 Rear Caliper Removal Inspection 9 17 Rear Caliper ...

Page 206: ...4 496 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 C...

Page 207: ... by 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 a...

Page 208: ... compensates 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 ...

Page 209: ...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 210: ... 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 211: ...nstall 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 5 in lbs 0 56 Nm 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 sl...

Page 212: ...s 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 thickness of the pad material Replace pads if worn beyond the service limit Measure Thickness Front Brake Pad...

Page 213: ...fy fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install wheels and torque wheel nuts Front Wheel Nut Torque 20 ft lbs 27 Nm BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and s...

Page 214: ...nting bolts to soften the bolt locking agent 18 ft lbs 25 Nm new bolts have pre applied locking agent 2 Remove bolts and disc 3 Clean mating surface of disc and hub 4 Install disc on hub 5 Install new bolts and tighten to specified torque Front Brake Disc Mounting Bolt Torque 18 ft lbs 25 Nm CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destro...

Page 215: ...n inward and slip brake pads past edge 3 Remove mounting bracket pin assembly and dust boot Remove Mounting Bracket 4 Remove piston dust seal and piston seal 5 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body Clean Components ...

Page 216: ...FRONT CALIPER REASSEMBLY 1 Install new O rings A in the caliper body B Be sure groove is clean and free of residue or brakes may drag upon assembly A B C D 2 Coat piston with clean Polaris DOT 3 Brake Fluid C Install piston D with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins with Polaris Premium A...

Page 217: ...g Bolt 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 5 9 6 5 Install wheels and torque wheel nuts to specification Front Wheel Nut Torque 20 ft lbs 27 Nm ...

Page 218: ...EXPLODED VIEW Caliper Mount Piston Bushing Boot Square O Rings Socket Set Screw Boot Bushing Brake Pads Caliper Assembly Bleeder Screw APPLY POLARIS ALL PURPOSE GREASE APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT 3 3 3 35 60 IN LBS 4 6 5 NM ...

Page 219: ...rt 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 ba...

Page 220: ... 41 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 burnish...

Page 221: ...and 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 Insp...

Page 222: ...king 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 To...

Page 223: ...ariance 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 contamin...

Page 224: ... Rear Caliper Seals Slide Pins Torque 30 35 ft lbs 41 48 Nm Piston Bushings Seal Bracket Pads Front Caliper Snap Ring APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT 3 3 3 REAR AUXILIARY MASTER CYLINDER Frame Bushing Bushing Washer Washer Screw Spring Screw Rear Brake Master Cylinder Rear Brake Line Seal Bolt Brake Reservoir Clamp Reservoir Hose Brake Mount ...

Page 225: ...ant Sensor Tests 10 12 Fan Motor Tests 10 12 Fan Control Switch Test 10 13 Electronic Throttle Circuit System Operation 10 13 Ignition System Testing Flow Chart 10 14 Ignition System Troubleshooting 10 15 CDI Output Tests 10 15 Charging System Testing 10 15 10 17 Battery Activation Service 10 18 10 21 Head Light Brake Light Lamp Service 10 21 10 22 Starter System Testing 10 22 Starter System Troub...

Page 226: ...Ignition Controller Wire Cap COMPONENT LOCATION Magnetic Switch Spark Plug LR390 Bumper Area FLYWHEEL IDENTIFICATION The flywheel can be identified by the tag located on the flywheel The tag indicates the Polaris Part Number the production date direction of rotation and has timing marks to time the engine Polaris Production Date Part Number Direction of Rotation Flywheel Identification Stamp Locat...

Page 227: ...e proper jack for the test being performed i e 10A jack for current readings Refer to the Owner s manual included with your meter for more information GPay attention to the prefix on the multimeter reading K M etc and the position of the decimal point GFor resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply TIMING CHECK PROCEDURE 1 The ignit...

Page 228: ...bove or below 5000 Use the point of maximum advance when checking ignition timing TRIGGER COIL GAP Measure trigger coil gap with a feeler gauge The gap should be 022 028 inch 56 71 mm Measure Trigger Coil Gap Trigger Coil Gap 022 028 inch 56 71 mm GEAR POSITION INDICATOR SWITCH TEST High Range Neutral Reverse F Low Range C B A D High Low Neutral Reverse Park Switch A B C D E F TRANSMISSION SWITCH ...

Page 229: ...he total 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 th...

Page 230: ...ndicates 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...

Page 231: ...ION 1 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 c...

Page 232: ...CT 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 Input 8 ...

Page 233: ... 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 TEST 2 N OK Y RE...

Page 234: ...OIL WIRING FOR SHORT 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...

Page 235: ...ds 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 PLAYS NO ROL...

Page 236: ... 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 air is t...

Page 237: ...ally closed switch and is held in the open position 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...

Page 238: ...ing an ohmmeter The coil mount should have good continuity to ground on the engine 0 2 W 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 300W Cap removed 6300W Are these values within specs Replace the ignition c...

Page 239: ...WITH 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 d...

Page 240: ...tral 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 approximat...

Page 241: ...tage 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 E...

Page 242: ...ery Never add electrolyte 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 st...

Page 243: ...henever 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 ...

Page 244: ...e and 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 ra...

Page 245: ...Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be 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 head...

Page 246: ... adjusting 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 Die...

Page 247: ...r 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 connecti...

Page 248: ...mber to subtract meter lead resistance 2 Measure resistance between insulated brush and starter housing Reading should be infinite OL Inspect insulation on brush wires for damage and repair or replace as necessary 3 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The electrical input post must stay with ...

Page 249: ...lace 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 Check commutator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replaceme...

Page 250: ...rive end cap if necessary Roller Bearing Seal 6 Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate STARTER REASSEMBLY CONT D 7 Using a non petroleum grease lubricate brush end bushing and install shims Dielectric Grease PN 2871329 8 Align brush plate and install cover and screws 9 Lightly grease pinion shaft and install pinion spring st...

Page 251: ...e with the end bent in a hook and pick the old spring out of its channel Slide it off the end of the shaft Slide the new spring over the overrun clutch and into the spring groove Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick out shoes 2 Remove the retaining ring thrust washer spring retainers and clutch return spring Screw the overrun ...

Page 252: ...ion Description Ref 1 Rubber Ring 10 Gear Assembly 2 Brush Spring 11 Though Bolt 3 Thrust Washer 12 Cover 4 Gear Assembly 13 Stopper 5 O Ring 14 Snap Ring 6 Brush Complete 15 Washer 7 O Ring 16 Flange Bolt 8 Thrust Washer 17 Thrust Washer 9 Shaft Complete 18 Flange Bushing Do not reuse Replace with new parts ...

Page 253: ...t Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery to solenoid wire 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 ...

Page 254: ...ELECTRICAL ELECTRICAL 10 30 NOTES ...

Page 255: ...ELECTRICAL 10 31 WIRING DIAGRAM 2002 SPORTSMAN 700 ...

Page 256: ...ELECTRICAL 10 32 WIRING DIAGRAM 2003 SPORTSMAN 600 700 ...

Page 257: ...rake Pad Inspection 2 27 Brake Pad Installation Rear 9 16 Brake Pad Removal Front 9 8 Brake Pad Removal Rear 9 15 9 16 Brake System Inspection 2 26 Brake System Operation 9 4 Brake Auxiliary Hydraulic 2 27 Brake Auxiliary Testing 2 27 Brakelight Lamp Replacement 10 22 Breather Filter Maintenance 2 20 Breather Hose Inspection 2 20 Brush Replacement Starter Motor 10 24 C Cam Gear Assembly 3 38 Cam G...

Page 258: ...vice 6 22 EBS Driven Clutch Disassembly 6 18 6 20 EBS Exploded View 6 3 EBS Moveable Sheave Bushing Inspection 6 18 EBS One Way Drive Clutch Inspection 6 17 6 18 EBS One Way Driven Clutch Inspection 6 18 Electrical Service Notes 10 3 Electrical Special tools 10 3 Engine Accessible Components 3 7 Engine Bottom End Disassembly 3 29 3 30 3 32 Engine Bottom End Disassembly Inspection 3 44 Engine Break...

Page 259: ...Front Rear 2 9 Gearcase Operation 4X4 Front 7 9 Gearcase Removal Front 7 8 Gearcase Removal Rear 7 24 Glossary of Terms 1 17 1 18 H Headlamp Service 10 21 10 22 Headlamp Switch Testing 10 22 Headlight Adjustment 10 21 High Engine Coolant Temperature 10 5 High Low Battery Voltage 10 5 Honing to Oversize 3 17 Hour Meter 10 5 Hub Installation Rear 7 18 Hub Removal Rear 7 17 I Idle Speed Adjustment 2 ...

Page 260: ...Arm Inspection 3 19 S Sediment Tube Maintenance 2 19 Shift Linkage Adjustment 2 11 Shift Weights 6 10 Side Panel Removal 5 9 Spark Plug Maintenance 2 16 Special Tools 2 6 4 4 7 3 9 2 Special Tools CH 3 3 7 Special Tools PVT 6 4 Specifications Brake 9 2 Specifications Cooling System 3 14 Specifications Drive Clutch Spring 6 9 Specifications Model 1 6 1 7 1 8 1 9 1 10 1 11 Specifications Torque Brak...

Page 261: ...2 8 3 Trigger Coil Gap 10 4 Troubleshooting Brakes 9 19 Troubleshooting Cooling System 3 57 Troubleshooting Engine 3 56 3 57 Troubleshooting Fuel System Carb 4 12 Troubleshooting Ignition System 10 15 Troubleshooting Spark Plug 3 56 Troubleshooting Starter System 10 23 U U Joint Assembly 7 7 U Joint Disassembly 7 7 Unit of Measure Conversion Table 1 15 V Valve Inspection 3 22 Valve Lifter Removal ...

Page 262: ...PN 9918066 Printed in USA ...

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